Internee
3600 Bar Code Label Printer
P/N 062905-001
Intermec® Corporation
6001 36th Avenue West
P.O. Box 4280
Everett, WA 98203-9280
U.S. technical and service support: 1-800-755-5505
U.S. media supplies ordering information: 1-800-227-9947
Canadian technical and service support: 1-800-688-7043
Canadian media supplies ordering information: 1-800-268-6936
Outside U.S. and Canada: Contact your local Intermec service supplier.
The information contained herein is proprietary and is provided solely for the purpose of allowing
customers to operate and/or service Intermec manufactured equipment and is not to be released,
reproduced, or used for any other purpose without written permission of Intermec.
Information and specifications in this manual are subject to change without notice.
© 1995 by Intermec Corporation
All Rights Reserved
The word Intermec, the Intermec logo, Label Debut, and CrossBar are trademarks of Intermec
Corporation.
The name Centronics is wholly owned by GENICOM Corporation.
IBM is a registered trademark of International Business Machines Corporation.
Throughout this manual, trademarked names may be used. Rather than put a trademark (™)
symbol in every occurrence of a trademarked name, we state that we are using the names only in an
editorial fashion, and to the benefit of the trademark owner, with no intention of infringement.
The software contained in the 3600 printer and the accompanying materials are copyrighted.
Unathorized copying of the software, including software that has been modified, merged, or
included with other software, or the written materials is expressly forbidden without the prior
written consent of Intermec. All right, title, and interest in all copies of this software are and shall at
all time remain the sole and exclusive property of Intermec. Customer may be held legally
responsible for any copyright infringement that is caused or encouraged by its failure to abide by
these terms.
Contributors
Technical Writer:
Editor:
Technical Illustrator:
Technical Reviewers:
Robert Shaw
Craig Thompson
George Wilson
Cathy Aragon
Pixie Austin
Daniel Clark
John Cramer
Allen Crowe
Stephen Eckert
Pat Helton
Laura McCluer
Ed Millet
Art Millican
Matt Roberts
Joe Wade
///
Contents
Contents
Before You Begin xi
Safety Summary xi
Warnings and Cautions xii
Purpose of This Manual xii
Additional Information xv
General Information
Overview of the 3600 Printer 1-3
3600 Features 1-4
3600 Printer Specifications 1-4
Dimensions (no options installed) 1-4
Electrical Requirements 1-4
Printing Methods 1-4
Printing Speed 1-5
Printhead Specifications 1-5
Media Specifications 1-5
Ribbon Specifications 1-5
Environment 1-5
Self-Strip Specifications 1-5
Communications 1-6
Fonts and Graphics 1-6
Character Sets 1-6
Memory 1-6
Factory Default Settings 1-7
3600 Printer Options 1-7
Memory Expansion 1-7
Twinax Interface 1-7
Coax Interface 1-8
Parallel Interface 1-8
Network Connectivity 1-8
Kanji/Katakana Character Support 1-8
Batch Takeup 1-8
3600 Printer Maintenance Manual
Principal Functional Parts 1-9
Basic Printer Setup and Operation 1-11
Front Panel Operation 1-11
Over-Temperature 1-11
Media or System Faults 1-12
Feed/Pause Pushbutton 1-12
Checking the Printer Configuration 1-12
DIP Switch Settings 1-13
Connecting the Printer to a Computer 1-13
Printing 1-14
Using Label Debut 1-14
Using Third-Party Software 1-14
Using the Printer Command Set 1-15
B
Preventive Maintenance
Preventive Maintenance Actions and Intervals 2-3
Inspecting the Printer 2-4
Cleaning the Printer 2-4
Removing the Media Cover 2-5
Cleaning the Printhead 2-6
Cleaning the Rollers and Tear Bar 2-8
Cleaning the Media Guides and Media Path 2-9
Cleaning the Label and Ribbon Sensors 2-11
Cleaning the Printer Covers 2-12
Testing and Adjusting
Testing the Printer 3-3
Running Test and Service Mode at the Printer 3-4
Setting DIP Switches 3-4
Printing Test Labels 3-7
Running Test and Service Mode From a Host Computer 3-11
Testing Printer and Host Communications 3-12
VI
Contents
H
Adjusting the Printer 3-13
Adjusting the Print Bias for Print Quality 3-14
Adjusting the Print Intensity 3-15
Adjusting the Printhead Adjustment Lever for Print Quality 3-16
Adjusting the Label Mark Sensor 3-17
Adjusting the Label Gap Sensor 3-19
Adjusting the Label Taken Sensor 3-20
Aligning the Printer 3-21
Aligning the Rollers 3-22
Aligning the Printhead 3-23
Aligning the TTR Supply Hub 3-25
Troubleshooting
About Troubleshooting and Repair 4-3
Troubleshooting Tips 4-3
Where to Start 4-3
Repair 4-3
Troubleshooting Checklist 4-4
Error Handling 4-5
Syntax Errors 4-5
Parameter Errors 4-5
Image Overrun Errors 4-5
Invalid Numeric Character Errors 4-6
Insufficient Storage RAM Errors 4-6
Error Codes 4-6
Printer Operation Problems 4-9
Print Quality Problems 4-10
Communications Problems 4-12
Environmental Problems 4-13
Electrostatic Discharge (ESD) 4-13
Electromagnetic and Radio Frequency Interference 4-14
Ground Loops Between Equipment 4-14
Inadequate Earth Ground 4-14
AC Power Problems (Surges, Sags, Spikes, Noise, and Outages) 4-15
Miscellaneous Problems 4-16
VII
3600 Printer Maintenance Manual
m
LiJ
Remove and Replace Procedures
Replacing Printer Components 5-3
Replacing the Lithium Battery 5-4
Replacing the Printhead 5-5
Replacing the Bezel PCB 5-6
Replacing the Main PCB 5-8
Replacing the Kanji/Katakana Option PCB 5-9
Replacing the Label Mark Sensor 5-10
Replacing the Label Taken Sensor 5-12
Replacing the Label Gap Sensor 5-13
Replacing the TTR Drive Roller and Gear/Pulley 5-15
Replacing the TTR Takeup Hub, Clutch/Pulley, and Belt 5-18
Replacing the TTR Supply Hub and Adjusting Plate 5-20
Replacing the Platen Roller and Gear 5-22
Replacing the Liner Drive and Takeup Components 5-24
Replacing the Stepper Motor 5-30
Replacing the AC Plug/Input Filter 5-31
Replacing the Power Switch/Circuit Breaker 5-32
Replacing the Transformer 5-33
PCB Drawings and Schematics
Replacement Parts
VIII
Contents
Appendix
Functional Description of the 3600 Mechanics A-3
Functional Description of the 3600 Electronics A-4
Power Supply A-4
+5V A-4
+40V A-4
+24V A-4
Power Fail Detection A-5
Battery A-5
Battery Life Calculations A-5
Reset A-5
Motor Driver A-6
Processor A-7
Chip Selects A-7
TPU A-7
QSM A-8
Interrupt Priority Levels A-8
Crystal A-8
Memory A-9
Static RAM A-9
EPROM A-9
DRAM A-9
Communications Interface A-10
A/D Converter A-10
DIP Switches A-10
ASIC and I/O Option Interface A-10
Address/Data Multiplexor A-10
Chip Select Generation A-11
I/O Option Connector A-11
FIFO A-11
Front Panel Interface A-11
Debug Interface A-11
Functional Description of the 3600 Software A-14
Band Buffering and Font Caching A-14
Image Band Buffering A-14
Image Band Example A-15
Font Caching A-18
Print Energy Compensation A-18
Digital Thermal Compensation A-18
Global Compensation A-18
IX
Before You Begin
Before You Begin
This section describes the purpose and arrangement of this manual to you. It is
intended to bring to your attention, important general safety concerns, specific
warnings and cautions, and sources of additional information.
Safety Summary
Your safety is extremely important. Read and follow all of warnings and
cautions in this book before handling and operating Intermec equipment. You
can be seriously injured, and equipment and data can be damaged if you do
not follow the safety warnings and cautions.
Do Not Repair or Adjust Alone Do not repair or adjust energized equipment
alone under any circumstances. Someone capable of providing first aid must
always be present for your safety.
First Aid Always obtain first aid or medical attention immediately after an
injury. Never neglect an injury, no matter how slight it seems.
Resuscitation Begin resuscitation immediately if someone is injured and stops
breathing. Any delay could result in death or permanent injury. To work on or
near high voltage, you should be familiar with approved industrial first aid
methods.
Energized Equipment Never work on energized equipment unless you are
authorized by a responsible authority. Energized electrical equipment is
dangerous. Electrical shock from energized equipment can cause death. If you
must perform authorized emergency work on energized equipment, be sure
that you comply strictly with approved safety regulations.
XI
3600 Printer Maintenance Manual
Warnings and Cautions
The warnings and cautions in this manual use the following format and
address the issues described:
A Warning
A warning alerts you of an operating procedure, practice, condition,
WARNING or statement that must be strictly observed to avoid death or
serious injury to the persons working on the equipment.
Caution
A caution alerts you to an operating procedure, practice, condition,
CAUTION or s t a t emen t th a t must be strictly observed to prevent equipment
damage or destruction, or corruption or loss of data.
Purpose of This Manual
The purpose of this maintenance manual is to provide the information you
need to clean, adjust, and repair the Intermec 3600 Bar Code Label Printer.
Who Should Read This Manual?
This manual is written for experienced electronic technicians trained by
Intermec, who will service and, if necessary, repair the 3600 printer. Detailed
operating instructions and specific related information is provided in the 3600
Bar Code Label Printer User's Manual.
This document is not intended to support user operations or persons untrained
in troubleshooting and repair. You should have a working knowledge of
electronics with an advanced understanding of PCs, DOS, data
communications, and bar code applications. It is assumed that you are familiar
with the installation, programming, and operation of the Intermec 3600 Bar
Code Label Printer and all of its options, including a working knowledge of the
Label Debut (or Label) software tool.
XII
Before You Begin
How This Manual Is Organized
You will find the following information in the referenced section:
For information about:
A basic description of the 3600
Scheduled cleanings and checks
Making sure the printer is operating
correctly and providing quality results
Problem solving
Removing and replacing components
Main PCB drawings and diagrams
Spare parts
Theory of operation
Refer to:
Chapter 1 - An illustrated overview of
the 3600 printer; listing printer
features, specifications, and options,
identifying primary parts, and
summarizing some setup and
operating information.
Chapter 2 - Actions, intervals, and
illustrated preventive maintenance
procedures.
Chapter 3 - Procedures for running
printer tests printing test labels,
printing out the configuration settings,
and for making printer adjustments
and alignments.
Chapter 4 - Information for
identifying, duplicating, isolating, and
eliminating conditions or failures in
the printer environment or the printer
components.
Chapter 5 - Instructions for the
removal and replacement of key
components.
Chapter 6 - Engineering drawing and
schematic diagram of the main PCB.
Chapter 7 - Two lists of the spare
parts: one in ascending part number
sequence and one alphabetically by
description, keyed to exploded
illustrations of the printer. Part
numbers for tools and documentation
are also provided.
Appendix - functional descriptions of
the 3600 mechanics, electronics, and
firmware.
XIII
3600 Printer Maintenance Manual
Terms and Conventions
The following terms and conventions occur throughout this manual. A
complete glossary of terms is provided in the 3600 Bar Code Label Printer User's
Manual.
Terms
• "Backing" (or liner) refers to the silicon release portion of the media that
carries the label.
• "Host" refers to any computer that the printer is connected to.
• "TTR" refers to the thermal transfer ribbon used when the printer is in
thermal transfer rather than direct transfer mode.
• "Media" is the stock on which the printer prints labels. Media can be made
of plain paper, polyester, thermally reactive paper, or other materials with
adhesive backing.
Conventions
The following conventions are used throughout this manual for operating
procedures and descriptions of the printer.
• Downloaded commands appear in the order that you enter them into the
printer with the following conventions:
Convention Description
< > Angle brackets < > enclose mnemonic representations of
ASCII control characters. For example, <ETX> represents
the ASCII "End of Text" control character.
{ } Braces {} enclose variable data. For example, {n} signifies a
variable for which you can designate a constant value.
I J Brackets around a word or letter represent a key on your
keypad. For example, [Tab] represents the Tab key and [M]
represents the letter M key.
[ ]-[ ] When two keys are joined with a dash, press them
simultaneously. For example, if you see the command
[Ctrl]-[C], press the two keys at the same time.
E3;F3 Enter all characters not enclosed in brackets by pressing an
individual keypad key. For example, E3;F3; is entered as
[E][3][;][F][3][;] with the E and the F in uppercase.
XIV
Before You Begin
Additional Information
The following documents may be of interest or help to you in servicing the
3600 printer.
3600 Bar Code Label Printer User's Manual (P/N 062732)
Label Debut User's Manual (P/N 062982)
Data Communications Reference Manual (P/N 044737)
The Bar Code Book by Roger C. Palmer
XV
General Information
General Information
This chapter identifies basic features, options, and technical specifications of the
3600 printer. It names principal functional parts and reviews basic printer setup and
operation.
Overview of the 3600 Printer
The Intermec 3600 is a microprocessor-based thermal printer that prints
standard bar code or 2D symbology, human-readable characters, graphics,
lines, and borders on 3-inch (7.62 cm) to 6.6-inch (16.8 cm) wide continuous
feed label stock.
The 3600 prints directly to thermal label media or can print on regular label
media with the use of a thermal transfer ribbon (TTR).
The 3600 supports applications that need a wider print capability than the
Intermec 3400 Bar Code Label Printer can provide.
1-3
3600 Printer Maintenance Manual
3600 Features
The 3600 printer's features are summarized in the following list:
Print speed from 2 to 5 ips
Programmable, nonvolatile printer configuration
Bitmap font capabilities
Outline/vector font support
User selectable gap feature for fonts
2D symbology support (Code One, PDF 417, and Maxicode)
128k (standard), 512k (optional) storage memory
Autoselection of Intermec protocols
Printable control characters
Image banding and memory management
Dot-by-dot digital thermal compensation
Self-strip or continuous print (with internal rewind)
Media sensitivity numbering system
Wide range of label media
Label Debut™ label design software
3600 Printer Specifications
The specifications and performance parameters for the 3600 printer are
itemized in this section.
Dimensions (no options installed)
Height 11 inches (27.9 cm)
Width 12 inches (30.5 cm)
Length 17 inches (43.2 cm)
Weight 45 pounds (20.3 kg)
Electrical Requirements
Input Voltage 100, 115, or 230 VAC ± 10%
Frequency 47 to 63 Hz
Printing Methods
Direct Thermal
Thermal Transfer (thermal transfer ribbon (TTR) required)
1-4
General Information
Printing Speed
Maximum 5 ips (50.8 mm per second)
Minimum 2 ips (127 mm per second)
The print speed can be changed in 1 ips increments only: 2, 3, 4, or 5.
Printhead Specifications
Element size 0.00492 inch square (0.13 mm)
Width 6.6 inches maximum print (168 mm)
Resolution 203 dots per inch (8 dots per mm)
# of Elements 1344 per printhead
X dimensions 10 mil to 50 mil or 0.25 mm to 1.27 mm,
5 mil (0.13 mm) in drag mode with specified media
Media Specifications
Roll 6,000 linear inches (152 m)
Length 0.5 inch (13 mm) to 17 inches (432 mm) (stripped media)
Width 3.0 inch (76 mm) to 6.7 inches (170 mm)
Thickness 0.012 inches (0.3 mm) maximum
Diameter 8.38 inch maximum diameter (213 mm)
Ribbon Specifications
Roll 6,000 linear inches (152 m)
Widths 3.0 inches (76 mm)
4.1 inches (104 mm)
5.4 inches (137 mm)
6.7 inches (170 mm)
Diameter 2.25 inches maximum (57 mm)
Environment
Operating 50°F to 104°F (10°C to 40°C)
Humidity 10% to 90% noncondensing
Self -Strip Specifications
The liner takeup hub can spool the backing of an entire 6,000-inch roll of
media.
Peel Release 10 to 50 grams
1-5
3600 Printer Maintenance Manual
Communications
Asynchronous RS-232C, RS-422, RS-485 interfaces
Serial ASCII code
Hardware (Ready/Busy) flow control
XON/XOFF protocol
Intermec Standard Block protocol
Polling Mode D protocol
Multi-Drop protocol
Baud Rates: 1200, 2400, 4800, 9600, 19200
Fonts and Graphics
5x7, 7x9, 7x11, and 10x14 86XX compatible fonts
2 bitmap OCR fonts
3 bitmap fonts measured in point sizes 8, 12, and 20
1 outline font
12 monospaced bitmap fonts
Kanji/Katakana bitmap font card (option)
Kanji/Katakana bitmap and outline font card (option)
UDF size of 4 inches (101.6 mm) maximum
UDC size of 4 inches (101.6 mm) maximum
Character Sets
US ASCII Norwegian/Danish
UK ASCII
Swedish / Finnish
German
Italian
French
Spanish
Swiss
Memory
Base
512K of DRAM for imaging
128K of SRAM for storage
Optional
512K of SRAM for storage
1-6
General Information
Factory Default Settings
The following is a list of the factory default settings for the 3600 printer:
Configuration
Default Setting
Preamble Character
Disabled
Postamble Character
Disabled
Auto-Transmit 1
Disabled
Auto-Transmit 2
Disabled
Auto-Transmit 3
Disabled
Message Delay
ms
Power-Up Mode
Advanced mode
End-of -Print Skip Distance
100 dots
Top of Form
20 dots
Media Sensitivity
420
Number of Image Bands
3
Maximum Label Length
1000 dots
Printer Character Set
US ASCII
Label Retract
Enabled
Print Speed
3 ips
Label Stock Type
Die-cut
Intercharacter Delay
ms
3600 Printer Options
The 3600 you are servicing can be equipped with one or more of the following
options:
Memory Expansion
Storage memory for formats, pages, graphics, and fonts can be increased to
512K of battery backed static RAM. This option provides an additional 512K of
nonvolatile bulk storage to hold more formats, fonts, or bitmap graphics. It also
increases the printer's image buffering capabilities.
Twinax Interface
Allows connection of the 3600 printer to IBM Twinax systems. The printer
emulates an IBM 5256 Model 1 printer and can operate with an IBM System
34/36/38 or AS/400 host computer.
1-7
3600 Printer Maintenance Manual
Coax Interface
Allows connection of the 3600 printer to IBM coax systems. The 3600 emulates
an IBM 3287 printer by connecting the printer to IBM 3270 Type A coax cable
computer systems operating in the VTAM (CICS/IMS/TSO) or 8100 (DPPX)
environments. Connection can be made to an IBM 3174/76/99 system
controller/multiplexer.
Parallel Interface
This option lets the user connect the 3600 to a PC through any Centronics™
parallel interface in addition to the standard serial interface.
Network Connectivity
Using the Parallel Interface option and an Ethernet or other network adapter,
the 3600 can be connected to a network.
Kanji/Katakana Character Support
The 3600 has two Kanji/Katakana options: bitmap fonts only, or outline and
bitmap fonts. Users shipping finished materials or work in process materials to
Japan can meet Japanese label requirements for Kanji/Katakana (JIS
Interleaved 2 of 5).
Batch Takeup
A larger diameter liner takeup hub permits printed labels to be spooled for
later use without causing as much label curl as the smaller diameter hub. The
maximum takeup outside diameter is 5 inches.
1-8
General Information
Principal Functional Parts
The following illustrations identify the common name and location of the major
functional elements of the 3600 printer.
Front Panel
Media
window
Media access
door
Media
cover
Darkness adjust
control
DIP switches
Optional I/O
~ ~ board port
Serial
communications port
AC power cord
receptacle
Power on/off
switch
Fanfold media
access slot
1-9
3600 Printer Maintenance Manual
Media post
TTR supply hub
TTR takeup hub
TTR roller
Tear bar I
Platen
roller
Self-strip/
liner roller
3E 9Uide
Thermal
printhead
Upper media
guide
Lower media
TTR/ribbon
Media roll
Media
roll retainer
Media
post
Lower media
guide
Media
access door
Printhead lift
lever
Self-strip/
liner roller Tear
bar
1-10
General Information
Basic Printer Setup and Operation
Detailed operating instructions for the 3600 printer are contained in the user's
manual. This section summarizes the following basic setup and operating
information for you as a quick reference:
• Front panel operations
• Checking printer configuration
• Connecting the printer to a computer
• Printing
Front Panel Operation
The three light emitting diodes (LEDs) on the printer's front panel (Power,
Alert, and Empty/Pause) indicate the conditions identified in the following
illustration:
Green LED-
Orange LED~
YellowLED-
-o
-o
Power
Alert
Empty/Pause
Feed/Pause
LED State
Indication
Off
Power off
On steady
Power on
Off
Printing or idle
On flashing
Over-temperature
On steady
System fault
Off
Printing or idle
On flashing
Paused
On steady
Media fault
Over-Temperature
If the printhead reaches an over-temperature condition, the Alert LED on the
printer flashes and the printer halts printing. Usually, you will not need to
intervene. If you allow the printer enough time to cool down, it normally
resumes operation on its own.
1-11
3600 Printer Maintenance Manual
Media or System Faults
If you are servicing a printer indicating a media or system fault, refer to
Chapter 4, "Troubleshooting," for information about the problem.
Feed/Pause Pushbutton
Operating the Feed/Pause button produces the following actions, depending
on what condition the printer is in:
Printer Condition
If the printer is idle:
If the printer is printing:
When the printer is first
powered on:
Operation/Function
Pressing and releasing the Feed /Pause button
causes the printer to feed out one label or a
minimum specified amount of media.
Pressing and holding the button down causes
media to feed continuously until the button is
released.
Pressing the Feed /Pause button twice takes the
printer offline. Press the button once more to
bring the printer online.
Pressing and releasing the Feed /Pause button
causes the printer to pause.
Subsequent pressing and releasing of the button
allows the printer to resume printing.
Pressing and holding the Feed /Pause button
down until the printer stops printing cancels the
current print job.
Pressing and holding the Feed /Pause button
down when turning printer power on places the
printer in the Test and Service mode and causes
the hardware configuration label to print.
Checking the Printer Configuration
The factory default settings for the 3600 printer are listed with the 3600
specifications in this chapter. These parameters are set using a combination of
DIP switch settings and downloadable printer commands, which are described
in the user's manual. Remember, you can print out hardware and software
configuration labels for statistics of the printer you are servicing.
1-12
General Information
DIP Switch Settings
The DIP switches on the rear panel of the printer control communications
parameters, media type configuration, and test and service functions. To
change settings, carefully position the plastic (breakable) switches to ON or
OFF with a small straight-slot screwdriver. The printer is shipped from the
factory in the standard configuration, with the 16 DIP switches set as shown in
the following illustration. When changing switch settings, you must cycle the
printer power from off to on for the changes to take affect.
Factory
Default Settings
Connecting the Printer to a Computer
To operate as intended, the 3600 must be interfaced with a computer (desktop
or laptop PC, local area network, AS400 or similar mainframe) with its serial
port configured for the communications protocol appropriate to the computer
interface. It is assumed that the correct interface (point-to-point, non-switched
modem, network, etc.) was achieved originally at installation and should have
a history of correct operation.
Refer to the 3600 User's Manual or contact an applications analyst for detailed
information about the type of installation you are servicing.
1-13
3600 Printer Maintenance Manual
Serial Port Settings
Parameter
Settings
Baud Rate
1200, 2400, 4800, 9600,
19,200
Parity
Even, Odd, None
Protocol
Intermec, XON/XOFF,
XON/XOFF with status
Device
AtoZ,
Address
0to5
Test and
Test Prints, Data Line
Service
Print, Cloning, Selective
Transfer, Memory Reset
Description
The rate, in bits per second (bps) at
which the host exchanges data with
the printer.
Checks each transmitted character for
errors.
The type of network used to connect
the printer, the host, and the rest of
the data collection system. Intermec
protocol includes Standard, Polling
Mode D, and Multi-Drop protocols.
Unique address for each device
connected using Multi-Drop protocol.
Provides printer diagnostics to the
host and prints test labels.
Printing
Regardless of your computer setup, you can use several methods to download
information to print labels. This section describes different ways you can
communicate with the printer. Refer to the 3600 User's Manual for detailed
information.
Note: Remember that these factors affect print quality: correct media, media sensitivity
setting, -print speed, and correct bar code orientation.
Using Label Debut
If you are using a point-to-point (printer-to-PC) connection to communicate
with the printer, the printer parameters can be easily set using the DOS-based
software package Label Debut. The Label Debut prompting screens assist you
in designing, printing, and editing labels. Refer to the Label Debut User's Manual
for more detailed information.
Using Third-Party Software
Your customer may be using third-party software to create label formats and
convert graphics into a UDC format that the 3600 printer can interpret. You can
use the same software to set the printer parameters.
1-14
General Information
Using the Printer Command Set
You can also create labels by downloading formats (designs) and data created
with the printer command set. The commands in the printer command set can
perform any function or activate any feature of the 3600 printer. You can use
the following methods to download commands:
• Downloading printer commands using DOS
• Using ASCII control characters or hexadecimal equivalents
• Using readable protocol/command characters
• Downloading printer commands with a PC communications program or
host terminal
Using a Novell network
1-15
Preventive Maintenance
Preventive Maintenance
This chapter identifies scheduled maintenance actions and provides illustrated
procedures for cleaning the 3600 printer.
Preventive Maintenance Actions and Intervals
Printer Component
Printer
Printhead
Preventive maintenance consists primarily of scheduled cleanings, but also
occassional performance checks and, possibly, adjustments based on those
checks. When you perform preventive maintenance, you should also conduct
the tests and adjustments described in Chapter 3, "Testing and Adjusting," that
will ensure the printer continues to deliver the highest quality output. You
need to perform preventive maintenance procedures at the intervals identified
to ensure a printer remains in proper working condition.
The following table is a schedule of recommended printer cleaning and
checking. Detailed cleaning procedures follow. Chapter 4, "Troubleshooting,"
contains instructions for performing various tests and adjustments.
Maintenance Action and Interval
Inspect the printer (and the rest of the data collection system) at every
service visit. Your inspection should include the types of items listed in the
following section.
Inspect after every roll of media. Clean after every roll (or 6,000 inches) of
media or more often if necessary. Inspect or test print quality every service
visit. Make any necessary adjustments.
Drive roller and tear bar
Media path, edge, and
guides
TTR drive roller
Liner drive roller
Clean after every five rolls of media. Using hi-tack adhesive requires
cleaning after every roll of media. If the customer uses tag stock or
continuous media, you may want to clean after every five rolls of media,
or more often if necessary. Harsh or dusty environments dictate the need
to clean more frequently. Inspect or test the operation of these printer
elements at every service visit. Make any necessary adjustments.
Media supply post
Label and ribbon sensors
Pinch roller
2-3
3600 Printer Maintenance Manual
Inspecting the Printer
You should routinely inspect the printer and the rest of the data collection
system. Your inspection needs to address the following and similar concerns:
• Make sure the printer is properly grounded.
• Make sure the printer's AC power source is within tolerance.
• Make sure the printer is clean.
• Make sure the printer is away from liquids.
• Inspect the work environment for cleanliness and arrangement. Large
electric motors, welders, and switching equipment can negatively affect
printer performance.
• Check the data collection network regularly for loose wires or poorly
installed connections. Be sure to replace corroded wires.
Cleaning the Printer
Use these procedures to access the printer parts and clean them. Heed the
warnings and cautions to prevent harm to yourself or damage to the printer.
You will need the following items to clean the printer correctly:
Isopropyl alcohol
Cotton swabs
Clean lint-free cloth
Soft bristle brush
Vacuum cleaner
Soapy water/mild detergent
A
WARNING
Warning
Energized electrical equipment is dangerous. Switch off the printer
power and remove the power cord before cleaning any part of the
printer. Failure to comply can result in injury or death.
2-4
Preventive Maintenance
Removing the Media Cover
Most of the cleaning procedures require that you remove the media cover.
To remove the media cover
1 . Place your fingers in the space at the lower center edge of the media cover
and pull the bottom of the cover away from the base of the printer.
2. Grasp the front of the media cover and lift the front of the cover upward.
Media
cover
Media cover
release
(between the two
notches)
3. Lift the media cover away from the printer.
2-5
3600 Printer Maintenance Manual
Cleaning the Printhead
Since the printhead must maintain close contact with the media to provide
good print quality, cleaning media debris from the printhead is very important.
Clean the printhead after every roll (or 6,000 inches) of media or whenever
necessary.
CAUTION
Caution
Do not use sharp objects such as knives or screwdrivers to scrape
the printhead clean. Cleaning with sharp objects will damage the
printhead. Clean with only a cotton swab, or a clean, lint-free cloth
or tissue moistened with isopropyl alcohol.
To clean the printhead
1 . Remove the media cover.
2. Raise the printhead by rotating the head lift lever clockwise until the
printhead releases.
TTR/
ribbon
Media roll
Printhead
lift lever
2-6
Preventive Maintenance
3. Remove the media from the paper path and the ribbon (if installed) from
the TTR supply and takeup hubs.
4. Use a cotton swab moistened with alcohol to remove any dirt, adhesive, or
debris from the print surface on the bottom of the printhead.
Thermal
printhead
3600M.012
5. Wait 5 to 10 seconds for the print surface to dry. Reload the media (and
ribbon if used).
6. Engage the printhead by rotating the head lift lever counterclockwise until
it locks in place.
7. If you are finished cleaning, install the media cover.
2-7
3600 Printer Maintenance Manual
Cleaning the Rollers and Tear Bar
Cleaning the platen roller and the tear bar preserves print quality by ensuring
close contact between the media and the printhead. The TTR roller, liner roller,
and media roller are cleaned in the same fashion to minimize general debris
and to maximize their efficiency.
To clean the rollers and tear bar
1 . Remove the media cover.
2. Raise the printhead by rotating the head lift lever clockwise until the
printhead releases.
3. Remove the media from the paper path and the ribbon (if installed) from
the TTR hubs.
4. Clean the rollers with a lint-free cloth moistened in isopropyl alcohol. Wipe
the cloth over the rollers, rotating each roller so that you clean all of it.
Media roll
roller
TTR
roller
\+4fr\ Platen
roller
Tear \
bar Lmer
roller
5. Clean both sides of the tear bar with a lint-free cloth moistened in isopropyl
alcohol. Remove all traces of dust, paper, and adhesive.
6. Reload the media (and ribbon if used) and then engage the printhead by
turning the head lift lever counterclockwise until the printhead locks.
7. If you are finished cleaning, install the media cover.
2-8
Preventive Maintenance
Cleaning the Media Guides and Media Path
Clean the media guides and media path regularly to keep debris off the media
surface and printhead where irregularities can spoil print quality or damage
the printhead. Cleaning the guides also helps prevent media skewing or
improper tracking as it travels through the paper path, which can result in
print problems. Always clean the media guides immediately after any label jam
in the printer.
Media debris may accumulate around the printer mechanism and along the
media path during normal operation of the printer. Clean debris away using a
soft bristle brush or vacuum cleaner. Remove all traces of dust, paper, and
adhesive. Clean the flat surfaces of the media path (including the edge guide)
with a lint-free cloth and isopropyl alcohol. Also remove all traces of dust,
paper, and adhesive from the pinch rollers on the media access door.
To clean the media guides and media path
1 . Remove the media cover.
2. Remove the media from the paper path and the ribbon (if installed) from
the TTR hubs.
3. Pull down and hold the spring-loaded lower media guide to open up the
media path.
4. Clean the lower media guide with a lint-free cloth moistened in isopropyl
alcohol.
Upper media
guide
Lower media
guide
2-9
3600 Printer Maintenance Manual
5. Use a lint-free cloth moistened with isopropyl alcohol to clean the upper
media guide. Be sure to remove all traces of debris.
6. Reload the media (and ribbon if used).
7. If you are finished cleaning, install the media cover.
To clean the pinch rollers
1. Open the media access door.
2. Use a cotton swab moistened with isopropyl alcohol to clean the pinch
rollers. Rotate the rollers to get any debris out of all of the grooves.
Pinch
Roller
Media
access
door
3600M.015
3. If you are finished cleaning, install the media cover.
2-10
Preventive Maintenance
Cleaning the Label and Ribbon Sensors
There are three label sensors and a ribbon sensor on the 3600 printer that
require cleaning: the label taken sensor, the label mark sensor, the label gap
sensor, and the ribbon motion sensor.
To clean the sensors
1 . Remove the media cover.
2. Raise the printhead by rotating the head lift lever clockwise until the
printhead releases.
3. Remove the media from the paper path and the ribbon (if installed) from
the TTR hubs.
4. Clean the label taken sensor and the label mark sensor with a cotton swab
moistened with isopropyl alcohol.
Encoder
decal
3600M.016
2-11
3600 Printer Maintenance Manual
5. Pull down on the lower media guide to expose the label gap sensor. Using
a soft bristle brush, remove all debris and dust from the label gap sensor.
6. Clean the label gap sensor with a cotton swab and alcohol.
7. Remove the electronics cover.
8. Very carefully clean the small ribbon motion optical sensor on the main
PCB and the black and white encoder decal on the TTR supply
clutch/ encoder assembly with a cotton swab moistened with alcohol.
9. Install the electronics cover.
10. Reload the media (and ribbon if used).
11. Engage the printhead by rotating the head lift lever counterclockwise until
it locks in place.
12. If you are finished cleaning, install the media cover.
Cleaning the Printer Covers
Clean the 3600 printer covers with a general purpose cleaner (soapy
water/mild detergent). Do not use abrasive cleansers or solvents. Be sure to
clean the transparent panel on the media cover so that you can see the media
supply inside the printer when the cover is closed.
2-12
Testing and Adjusting
Testing and Adjusting
This chapter contains procedures for testing the printer's performance as a quality
check during preventive maintenance, as a functional check when troubleshooting,
and as part of the repair process after replacing a printer component. This chapter
also contains procedures for making adjustments and alignments that ensure the
printer is operating normally.
Testing the Printer
If you are on site for preventive maintenance or are following up a corrective
action and the printer is working, start conducting quality checks from the Test
and Service mode. If you are on site for corrective maintenance, determine if
the problem lies with setup and process or the printer itself. Use the Test and
Service mode to determine if the printer can print. If it can, perform the
communications test.
The quality and efficiency of producing labels reveals if a printer is operating
correctly. In addition to analyzing labels to evaluate printer performance, the
3600 printer Test and Service mode allows you to conduct printer tests that
include printing test labels (illustrated in this section) with a fixed look so you
can compare them to an expected standard. The test labels can be used for
checking printhead alignment, printhead bias, dots out of specification, label
tracking, and ribbon wrinkling. Test and Service mode functions can be run at
the printer or from a host terminal through the use of commands.
If you find a printer lacking in performance after running your tests, check and
make the adjustments and alignments necessary to return the printer to normal
service. If you cannot get a printer working properly with an adjustment or
alignment, troubleshoot for a component failure.
Note: Making the alignments out of order can introduce, not solve -printing -problems.
Review the section about printer alignments before making any changes.
3-3
3600 Printer Maintenance Manual
Running Test and Service Mode at the Printer
Note: When the printer is placed in Test and Service mode, it prints out a hardware
configuration label, regardless of its initial DIP switch settings, and remains in Test
and Service mode until the power is switched off and the DIP switches are reset.
Momentarily pressing the Feed/Pause button during a test will cause the test to halt.
Holding the Feed/Pause button down will start a new run of whichever test you select.
To enter Test and Service mode and select test functions at the printer
1 . Switch off the printer power.
2. Set the DIP switches to select the function that you want to run.
3. Press down and hold the Feed/Pause button while powering on the
printer. The printer prints out a hardware configuration label.
4. Hold the Feed/Pause button down for 1 second. The test begins
immediately.
5. If you wish to perform another function, repeat Steps 1 through 4. The
function currently being executed is terminated and the new function
begins.
To exit Test and Service mode
1 . Switch off the printer power.
2. Return all DIP switches to their original settings.
3. Switch on the printer power.
Setting DIP Switches
Use the information provided in the following tables and examples to set the
DIP switches for the Test and Service mode function that you wish to perform.
The "0"s indicate that the switch is in the OFF position and the "l"s indicate
that the switch is in the ON position.
3-4
Testing and Adjusting
Test and Service Switch Settings
Top Ban k
= OFF 0FF
P
Hi
1 =ON
flf
'A' A 1 A
7J
A
j\
A
j\
5aaa
yj
A
J I
TESTS ON
1
2 3
4
5 6
7
8
1
2 3 4 5
6 7 8
Test Prints
Configurations
Hardware
A
Software
1
A
Test Labels
Print Quality
1
A
Pitch
1
1
A
Page
Single Page
1
B
B B B B
A
All Pages
1
1
1
1
1111
A
Format
Single Format
1
1
B
B B B B
A
All Formats
1
1
1
1
1111
A
UDC
Single UDC
1
B
B B B B
B B A
All UDCs
1
1
1
1111
1 1 A
Font
Single Font
1
1
B
B B B B
BOO
All Fonts
1
1
1
1
1111
1
Data Line Print
1
Cloning
Receiver
1
Sender
1
1
Selective Transfer
Receiver
1
1
Send Pages
Single Page
1
1
C
C
c
C C D D
D D D
All Pages
1
1
1
1
1
1111
1 1 1
Send Format
Single Format
1
1
D D
D D D
All Formats
1
1
1
1
1
1111
1 1 1
Send UDC
Single UDC
1
1
1
C
C
c
C C C C
COO
All UDCs
1
1
1
1
1
1
1111
1
Send Font
Single Font
1
1
C
C
c
C C D D
D D
All Fonts
1
1
1
1
1
1111
1 1 1
Send Configuration
1
1
1
Send Tables
1
1 1
Send All
1
1
1 1
Memory Reset
Page/Format
1
UDC/Font
1
1
Configuration
1
1
Tables
1
1
All
1
1
1 1
A: OFF = Batch of 1. ON = Batch of 100
B: Page/Format/UDC/Font number.
Least significant bit first
C: Source Page/Format/UDC/Font number. Least significant bit first.
D: Destination Page/Format/UDC/Font number
Least sig
nificant bit first.
3-5
3600 Printer Maintenance Manual
Test and Service Configuration Settings
Top Bank
Bottom Bank
= OFF
1 =ON
OFF \
ON
Label Rest Point
Adjust Forward
Adjust Backward
86XX Emulation
Advanced Mode
10 Mil
15 Mil
X Forms Adjust
Adjust Forward
Adjust Backward
Y Forms Adjust
1 1
1 O 1
1111
1110
o
N
N
N
N N
1
N
N
N
N N
o
1
1
1
1
N
N
N
N N
1
N
N
N
N N
N: Number. Least significant bit first.
N N N N N
Dot Increment Switch Settings
Bottom Bank
= OFF
1 =0N
OFF
ON
# of dot increments
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
3600M.022
3-6
Testing and Adjusting
Printing Test Labels
The test labels can be used for checking printhead alignment, printhead bias,
dots out of specification, label tracking, and ribbon wrinkling. The examples
show the DIP switch settings that select the illustrated label.
Hardware Configuration
The hardware configuration label is the first label printed when you enter Test
and Service mode. This label serves as a configuration reference as well as an
alphanumeric and alignment print test. This label contains the following
information and uses:
• Printer memory including both storage and image RAM.
• Printer mileage including inches processed and inches burned.
• Printhead settings including width, dot size, and burn pot setting.
• Firmware checksum, program, and version number.
• Vertical lines for evaluating printhead alignment.
To achieve the highest quality label, print the hardware configuration label at a
speed of 3 ips (inches per second).
3600 Hardware Configuration
Memory Installed
Storage RAM
128 kilobytes
Image RAM
382 kilobytes
Flash RAM
none
Mileage
Inches Processed
540
Inches Burned
204
Labels Cut
Printhead
Width
1344 dots
Dot Size
5.0 mil
Burn Pot Setting
213
Hardware Options
I/O Option
none
Internal Option
none
External Option
Self Strip
Firmware Checksum
ROMO (U9)
FAC3
ROM1 (U8)
OC3E
Program
062198
Version
1.1
ON
1 2 3 4 5 6 7 8
ON
1 2 3 4 5 6 7 8
OFF
OFF
3-7
3600 Printer Maintenance Manual
Software Configuration
This three-label set lists current configuration parameters that are set from the
host computer. It also lists defined pages, formats, graphics, fonts, and
installed options. This label serves as a configuration reference as well as an
alphanumeric and multiple label alignment and print test.
\
r \
r
Program Version :
1.1
PRINT SPEED - 3.0 IPS RIBBON SAVE - Disabled
BAUD RATE -9600
Pages Defined :
IMAGE BANDS -3 SELF STRIP - Disabled
DATA BITS - 7
Formats Defined :
0, 19
MAX LABEL LENGTH - 4 inches CUTTER - Disabled
MESSAGE LENGTH -255
Fonts Defined :
0, 1,2, 7,20 21,22,23,24,
25,30,31,32,33,34,35,36
37, 38, 39, 40, 41
LABEL STOCK - Infer- label gap DARK ADJUST -
MEDIA TYPE - Direct Thermal X FORMS ADUST -
PARITY - Even
STOP BITS - 1
Graphics Defined
none
/
MEDIA LENGTH - inches Y FORMS ADJUST - 10
CHARACTER SET - US ASCII LABEL REST POINT -
TRANSLATION - Disabled SENSITIVITY • 420
EMULATION - Disabled
LABEL RETRACT - Enabled
PROTOCOL - Xon/Xoff No Status
DEVICE ADDRESS -A
INTERNAL OPTIONS -none
EXTERNAL OPTIONS - Self Strip
ON
12 3 4 5 6 7 8
ON
12 3 4 5 6 7 8
Print Quality
This label contains bar codes and human readable fields that you can use to
determine whether the printer you are testing is attaining the best print quality
possible. If you notice problems with the print quality, check and perform the
adjustment and alignment procedures provided in this chapter to achieve
optimum printer performance.
o
o
= O
- 1 m
CO
CO
^=^
-^
^^
m
_. JU
^<:
^^_
SO
So
o
<_>
^^^
o
£B
O
^
en O
ON
-EL^ffiU
~E_q^
"ECtf
-E_q^
*E_q^
ON
12 3 4 5 6 7 8
OFF
OFF
3-8
Testing and Adjusting
Format
This label, which can be a test of a single format or can provide a two-label
sample of all the formats, has bar codes and human-readable fields that you
can use to determine whether the printer you are testing is attaining the best
print quality possible using a particular format.
CD 3600 TEST LABEL
^= 1 3600 TEST LABEL
3600 TEST LABEL
3600 TEST
mi mi inn inn iiiiiiiiiiiiiiiiiiiiii mi
DT / TTR PRINT QUALITY SAMPLE
ON
12 3 4 5 6 7 6
ON
1 2 3 4 5 6 7 8
Pitch
This label is a gray scale printout of every third dot. The test label should
present a regular pattern with dots that line up diagonally when held at an
angle. Look for irregularities that may signal a problem with the platen roller
or the media path. If the printhead is uneven or the print path is skewed, it will
be reflected in this label. Use this label to determine whether the printhead is
printing evenly, but use the actual customer format to pass /fail the printhead.
ON
12 3 4 5 6 7 8
ON
1 2 3 4 5 6 7 8
3-9
3600 Printer Maintenance Manual
Font
This is a multiple-label test of the available fonts. You can test a single font
(Font 20 shown) or all of the fonts. An all-font test will use a lot of media. It is
better that you test one font at a time to make your determinations.
f
/
o
CM
4
8 12
16 2
£ 1
o
LL
2
5
6
9 13
10 14
17 2
18 2\
3
7
11 15
19 23 \
V
/
/1 24 128 132 136 140
1 125 129 133 137 141
26 130 134 138 142
192 196 200 204
A A E i
193 197 201 205
\194 198 202 206
,A Q E I
131 135 139 143 14\ }5 199 203 207
J K1P
»1^0J
-fcCjU
ON
■di]
-OT
"M
^^
-bciu
"^^
ON
*UP
-a^
-^BU
These labels test the ability to download and correctly print single or multiple
pages (a group of labels always printed together) of label data from a host. The
data can be yours or the customer's, but you should include a test of the
customer's labels to determine whether the printer you are testing is attaining
the best print quality possible with the customer's data.
UDC
This label tests the ability to download and correctly print single or multiple
user-defined characters (bitmap graphic) from a host. The data can be yours or
the customer's, but you should include a test of the customer's labels to
determine whether the printer you are testing is attaining the best print quality
possible with the customer's data.
3-10
Testing and Adjusting
Running Test and Service Mode From a Host Computer
When conducting Test and Service mode functions from a computer, hardware
diagnostic information is uploaded to the host from the printer.
The following table describes the commands you would issue from a host
terminal to run the Test and Service mode. To select Test and Service mode
from Print mode, send <ESC>T from the host terminal.
Note: All commands in Test and Service mode end with the command terminator (;),
except the last command in a message.
Test and Service Mode Command Descriptions
Command Code
A
B
C
D
K
M
Q
Test
Transmit Ambient
Temperature*
Printhead Resistance
Test*
Print Pitch Label
Reset Printer
Configuration
Transmit
Transmissive Sensor
Value
Dark Adjust*
Transmit Paper Path
Open Sensor Value*
Transmit Reflective
Sensor Value
Transmit Printhead
Temperature Sensor
Value
Print Quality Label
R Exit Test and Service
* The printer ignores this command.
Description
Transmits the ambient temperature sensor output back to
the host. The value ranges from 00 to FF.
Causes the printer to begin the printhead resistance test. The
printer will respond with the ASCII character string "pass"
or "fail."
Causes the printer to print the pitch label.
Sets the printer configuration to the factory defaults.
Transmits the label gap output back to the host. Values
ranges from 00 to FF.
This command changes the darkness of the print on your
labels. It is for fine-tuning only.
Transmits the Paper Path Open switch value back to the
host. A value of indicates the paper path is open and a
value of 1 means it is closed.
Transmits the label mark reflective sensor output back to the
host. The values range from 00 to FF.
Transmits the Printhead Temperature Sensor output back to
the host. Values range from 00 to FF.
Causes the printer to print out the print quality program
and model number label.
Causes the printer to exit Test and Service mode.
3-1 1
3600 Printer Maintenance Manual
Test and Service Mode Command Descriptions (continued)
Command Code Test Description
S Transmit Printhead Transmits the average, maximum, or minimum printhead
Resistance Values* dot resistance value back to the host. Each value is a
numeric data string separated by a comma.
T Transmit Label Transmits the label taken sensor output back to the host.
Taken Sensor Value Values can range from 00 to FF.
U Transmit 40V Supply Transmits the 12V supply output back to the host. The
Value* values range from 00 to FF.
V Transmit 24V Supply Transmits the 24V supply output back to the host. Values
Value* can range from 00 to FF.
* The printer ignores this command.
Testing Printer and Host Communications
This is a simple test of host-to-printer communications. If this test fails, there
may be a problem with the printer serial port receiver circuitry or the setup.
To test host-to-printer communications
1 . Switch the printer power off. Return the DIP switch settings to the standard
configuration if they have been changed.
2. Press and hold the Feed/Pause button while powering on the printer. The
printer presents the hardware configuration test label.
3. Release the Feed/Pause button after the hardware configuration label is
printed. You are now in data line print mode within the Test and Service
mode.
4. Send down some characters from the host. At this point the printer does
not attempt to interpret any printer commands, but simply prints each
character and its hexadecimal equivalent as it is received. If you are using a
PC running DOS, send down the following strings of commands from the
DOS prompt:
Note: A Zis[Ctrl][Z].
\MODE COM1 : 96,E,7,1,N [Enter]
(to configure the serial port)
\COPY CON COM1 : [Enter]
(tells the PC to copy the following text to the COM1 port)
ABCDEF A Z [Enter]
(these characters are sent to the printer)
3-12
Testing and Adjusting
5. A good test will result in the following printout :
R B C D E F
41 42 43 44 4546
6. To enter normal print mode again, switch the printer power off and then on
again.
If this test does not work, recheck after you make sure that the DIP switches
are set to the default configuration and that the printer cable is securely
plugged into COM1 of your PC.
Note: If you are using a different platform to communicate with your -printer, refer to
your host computer user's manual and the 3600 Bar Code Printer User's Manual
for more detailed information about downloading commands.
Adjusting the Printer
The following procedures provide instructions for adjusting the print bias, the
print intensity (darkness), the label mark sensor, the label gap sensor, the label
taken sensor, and the printhead fine adjustment lever on the 3600 printer.
A Warning
Always disconnect the power cord before removing the electronics
WARNING cover unless a procedure requires the unit to be energized. Failure to
disconnect the power cord may result in injury or death due to
electric shock.
Caution
The printhead and integrated circuits on printer circuit boards in
CAUTION th* s equipment are sensitive to damage by electrostatic discharge
(ESD). Prevent ESD by always wearing skin contact ground straps
firmly attached to the equipment metal base assembly when
working inside of the equipment housing. Failure to comply can
result in damage to components or the printhead.
3-13
3600 Printer Maintenance Manual
Adjusting the Print Bias for Print Quality
Adjust the bias with a straight-slot screwdriver if the printhead is not making
even contact with the media. Using different width media, especially narrow
media, can result in uneven contact or a spot where there is no media between
the printhead and the platen roller. Extra wear and damage can occur if narrow
media is used for extended periods with incorrect bias.
To adjust the bias adjust screw
1. Remove the media cover and locate the bias adjust screw.
Printhead bias
adjust screw
3600M.030
2. Turn the bias adjust screw counterclockwise to compensate for light print
on the right side of the label; turn the bias adjust screw clockwise to
compensate for light print on the left side.
^>
If printing is light on
the right side of label,
turn the bias adjust screw
counterclockwise.
m
fl
^
If printing is light on
the left side of label,
turn the bias adjust screw
clockwise.
3. Install the media cover.
3-14
Testing and Adjusting
Adjusting the Print Intensity
Note: Before you adjust print intensity, verify the sensitivity rating for the media
matches the rating set in the printer.
Use the darkness adjust control in combination with the darkness adjust
command <SI>d to fine-tune the intensity of print on your customer's labels.
The fine adjustments compensate for variations in the media ("lot to lot"), the
printhead, or the printer. Set the darkness adjust control with a small straight-
slot screwdriver after entering the proper sensitivity number.
To adjust the print darkness control
1. Locate the darkness adjust control on the back of the printer. Make
adjustments with a small straight-slot screwdriver.
Turn the darkness
adjust control clockwise
1 | for darker density. Darkness
adjust control
Turn the darkness adjust
control counterclockwise
for lighter density.
2. Increase the darkness by turning the darkness adjust control clockwise or
decrease the darkness by turning the control counterclockwise. Run a test
print to evaluate the print quality.
3-15
3600 Printer Maintenance Manual
Adjusting the Printhead Adjustment Lever for Print Quality
The printhead adjustment lever is located at the end of the printhead pivot
bracket. It allows fine-tuning of the printhead fore/ aft position. The printhead
adjustment lever provides three stops forward movement of the printhead and
three stops backward movement from center position in 0.006-inch increments.
To achieve the best print quality, raise the printhead with the printhead lift
lever and position the printhead adjustment lever as shown in the illustration:
from the rear, adjust clockwise /left to move the printhead forward, or adjust
counterclockwise/right to move the printhead backward.
Printhead
adjustment
lever
3-16
Testing and Adjusting
Adjusting the Label Mark Sensor
The mark sensor detects the mark on the back of continuous media stock. The
output is then used to determine the start of print point. This sensor is located
under the label pathway across from the platen roller. Two adjustments affect
the performance of this sensor, its physical position and sensitivity. To perform
this procedure, you need the following tools:
• Digital multimeter
• #2 Phillips screwdriver
• Small straight-slot screwdriver
To position the label mark sensor
1 . Remove the media cover.
2. Use your finger to reach underneath the lower guide.
Platen
roller
Locate the label mark sensor
behind the platen roller near
the inboard edge of the printer.
Use your index finger to adjust ;
the label mark sensor.
Inboard edge
of printer.
The platen roller
is not shown
for clarity only
3-17
3600 Printer Maintenance Manual
Slide the mark sensor into a position that centers it over the label mark as
the media passes by. It is adjustable from the inboard edge of the extrusion
to one half of the paper path width toward the outboard edge.
To adjust the label mark sensor potentiometer sensitivity
1 . Remove the electronics cover
2. Switch on the printer power.
3. Enable the printer for mark sensing using the <SI>T{2} command.
4. Connect the positive lead of a digital voltmeter to TP18 (MARK) and the
negative end to TP14 (GND) on the main PCB.
R191
3600M.035
5. Place the white portion of a label under the mark sensor.
6. Adjust R191 on the main PCB so the voltage at TP18 is IV ± 0.2V.
7. Place the black mark portion of the label under the mark sensor.
8. The voltage at TP18 should now be greater than 2.5V.
9. Install the printer electronics cover and the media cover.
10. Check the printer for proper operation.
3-18
Testing and Adjusting
Adjusting the Label Gap Sensor
The label gap sensor output enables the software to determine the leading edge
of a label by detecting the label gap. The label gap is the space between labels
on the backing material. This reading enables the printer to properly position
the start of print point. To perform this procedure, you need the following
tools:
• Digital multimeter
• #2 Phillips screwdriver
• Small straight-slot screwdriver
To adjust the label gap sensor potentiometer
1 . Remove the media cover and the electronics cover.
2. Connect the positive lead of a multimeter to TP15 (GAP) and the negative
lead to TP14 (GND) on the main PCB.
R124
3600M.036
3. Switch on the printer power.
4. Insert the label backing only in the label gap sensor. Adjust R124 on the
main PCB so that the voltage at TP15 (GAP) is IV ± 0.2V.
5. Insert both the label and the label backing in the sensor. Verify that the
voltage at TP15 (GAP) is greater than 3V.
6. Install the printer electronics cover and the media cover.
7. Check the printer for proper operation.
3-19
3600 Printer Maintenance Manual
Adjusting the Label Taken Sensor
The label taken sensor output enables the software to determine that a label has
been taken by detecting the label's presence. To perform this procedure, you
need the following tools:
• Digital multimeter
• #2 Phillips screwdriver
• Small straight-slot screwdriver
To adjust the label taken sensor
1 . Remove the media cover and the electronics cover.
2. Connect the positive lead of a multimeter to TP19 (TAKEN) and the
negative lead to TP14 (GND) on the main PCB.
R190
DC
. iioorflro
IJ.III.r '0DD000D0I
I^Lli
D Q !
30| JLjf pl * 00
ooc oool " Ui tl oo
oo
Ooo
"
■ice of
DD □
DD □
3600M.037
3. Switch on the printer power.
4. Feed one label out of the printer so that it rests under the label taken sensor
in a correct orientation.
5. Adjust R190 on the main PCB until the voltage at TP19 is 1.2V + 0.2V.
6. Remove the label from under the label taken sensor.
7. The multimeter reading at TP19 should now read above 4.5V.
8. Install the printer electronics cover and the media cover.
9. Check the printer for proper operation.
3-20
Testing and Adjusting
Aligning the Printer
The following procedures provide instructions for aligning the rollers, aligning
the printhead, and aligning the ribbon supply hub on the 3600 printer.
Note: These alignments should be made in the sequence given. Performing them out of
order can introduce and not solve -printing -problems.
A Warning
Always disconnect the power cord before removing the electronics
WARNING cover unless a procedure requires the unit be energized. Failure to
disconnect the power cord may result in injury or death due to
electric shock.
Caution
Integrated circuits on printer circuit boards in this equipment are
CAUTION sensitive to damage by electrostatic discharge (ESD). Prevent ESD
by always wearing skin contact ground straps firmly attached to
the equipment metal base assembly when working inside of the
equipment housing. Failure to comply can result in damage to
components.
Caution
Align only one outboard plate at a time (either upper or lower) to
CAUTION P u * th e rollers back into factory alignment. If both plates are
loosened, it may not be possible to align the rollers outside of the
factory.
3-21
3600 Printer Maintenance Manual
Aligning the Rollers
You should perform this procedure every time an outboard plate is removed or
replaced. To perform this procedure, you need the following tools:
Note: If the printer you are servicing has upper outboard plate lntermec Part No.
062476-002 installed, you need to replace it with a new upper outboard plate lntermec
Part No. 063225-001 before you can perform the following roller alignment.
• Roller alignment tool, lntermec Part No. T43150
• #2 Phillips screwdriver
To align the rollers
1 . Switch off the printer power and remove the power cord.
2. Remove the media cover, the electronics cover, and the front bezel cover
(refer to Chapter 5, "Remove and Replace Procedures/'for detailed
instructions).
3. Raise the printhead with the printhead lift lever. Remove media and ribbon
if loaded.
4. Loosen the Phillips screws on the outboard plate that you are aligning.
Note: Align only one outboard plate at a time (either the upper or the lower) to put
the rollers back into factory alignment. If both plates are loosened, it may not be
possible to align the rollers outside of the factory.
5. Align the three holes in the roller alignment tool with the platen roller, the
liner roller, and the TTR roller. The fourth hole in the roller alignment tool
fits over the black plastic cap closest to the front of the printer.
3-22
Testing and Adjusting
6. When the tool fits properly on all of the rollers and the bushing, tighten the
screws on the outboard plate that you are aligning.
7. Reattach the front bezel cover. Ensure that the media access door operates
properly (snaps firmly shut) after the front bezel cover is installed.
8. Install the electronics cover.
9. Reload media (and ribbon if used).
10. Install the media cover and the power cord.
11. Switch on printer power and check for proper operation.
Aligning the Printhead
Align the printhead only if necessary. To perform this procedure, you need the
following tools:
• Printhead alignment tool, Intermec Part No. T43099
• 9/64-inch Allen screwdriver
To align the printhead
1. Switch off the printer power. Remove the power cord and the media cover.
2. Raise the printhead with the printhead lift lever. Remove media and ribbon.
3. Position the printhead adjustment lever clockwise /left two clicks during
the printhead alignment. Loosen the two Allen screws located on the
printhead yoke at the back of the printhead heatsink.
Printhead
adjustment
lever
3-23
3600 Printer Maintenance Manual
Note: This is a change in procedure from previous printhead alignment
instructions that directed the printhead adjustment lever to be in the neutral/center
position during alignment.
4. Install the printhead alignment tool and press the printhead assembly
down on the platen roller. Align the tool with the notches in the heat sink
and the printhead.
5. Alternately tighten the two 9/64 inch printhead yoke screws until secure.
6. Remove the printhead alignment tool.
7. Return the printhead adjustment lever to the neutral/ center position.
8. Reload media (and ribbon if used).
9. Install the media cover and the power cord.
10. Switch on printer power and test for proper printhead alignment by
printing out the print quality and pitch labels.
Place the cutouts
of the printhead
alignment tool onto
the shaft of the platen
roller.
Guide pin
(Align with the notches
on the heatsink and printhead.)
Printhead
alignment
tool
3-24
Testing and Adjusting
Aligning the TTR Supply Hub
You should align the TTR supply hub only if you are experiencing ribbon
wrinkle on full width ribbon after the rollers and printhead have been aligned.
To perform this procedure, you need the following tools:
• TTR supply hub alignment tool, Intermec Part No. T43149
• #2 Phillips screwdriver
To align the TTR supply hub
1 . Switch off the printer power.
2. Remove the media cover and the electronics cover.
3. Install the TTR supply hub alignment tool as shown.
Ribbon supply
hub alignment
tool
3600M.041
4. Tighten the alignment tool thumbscrew so the bushing tab is flush against
the bushing on the hub adjustment plate.
5. Loosen the two screws securing the hub adjustment plate.
6. Switch on the printer power.
7. Print a series of the same kind of labels that were having the ribbon
wrinkling problem. While they are printing, adjust the TTR supply hub up
or down (with the thumbscrew on the tool) until ribbon wrinkling is
eliminated.
3-25
3600 Printer Maintenance Manual
Note: If this adjustment does not eliminate ribbon wrinkling, try readjusting the
ribbon supply hub and realigning the printhead.
8. When an alignment is achieved that eliminates the ribbon wrinkling,
tighten the two screws on the hub adjustment plate.
9. Remove the tool and retest for ribbon wrinkling.
10. After the printer is correctly adjusted, switch off the power and reattach the
electronics and media covers.
3-26
Troubleshooting
Troubleshooting
This chapter provides you with information that will help you determine why a printer
may not be working and how to get it working again.
About Troubleshooting and Repair
Use the information in this chapter to identify the cause of a failing printer. It is
assumed that a printer is not working and that the troubleshooting actions
referenced in the user's manual were not used, failed to clear the problem, or
pointed to a printer malfunction.
Troubleshooting Tips
One of your first concerns is to duplicate and isolate the problem, to confirm if
the problem is the printer or not. Usually the printer was already working at
some point before you were called, so start with the last time it worked and
move forward logically, considering what might have changed since then. Do
not neglect to check simple things like, "Is the printer plugged in? Is there
power at the outlet? Are all of the connections good?" Spend a minute visually
examining the unit and considering the situation to see if anything obvious
stands out.
Where to Start
If you have not already done so, review the user's troubleshooting information
in this chapter and use tests from Chapter 3, "Testing and Adjusting," to
determine if and how the printer performs offline. If you have a working
installation at hand, consider the value and difficulties of trying the printer in a
known good working location. If you take this kind of action, be careful not to
cause additional problems or confuse your search.
If you decide you need to and can, carefully and logically swap known good
printers, subassemblies, or components with failing or suspect items as a
means of isolating the cause of the problem. Do not do this if you think any
known good item can be damaged.
Repair
Repair is whatever action you take to eliminate the problem that you are on site
to fix. If "repair" is the removal and replacement of a key printer component,
refer to Chapter 5, "Remove and Replace Procedures."
4-3
3600 Printer Maintenance Manual
Troubleshooting Checklist
If the host receives an error message or a functional problem with the printer is
encountered, the user's manual starts with the following:
• Check whether the printer sends an error code to the host in response to a
<BEL> command.
• If an error code is sent, find it in the "Error Codes" table in this chapter. Try
the solution given for the respective error code to attempt to correct the
problem.
• If the printer does not send an error message to the host, try to match the
symptom of your failure in the "Printer Operation Problems" or "Print
Quality Problems" tables in this chapter. Try the solution given for the
respective symptom to attempt to correct the problem.
• Clean the printer components and check all connections.
4-4
Troubleshooting
Error Handling
This section describes how the 3600 printer handles certain error conditions it
may encounter in printer or programming commands. Error codes sent to the
host, the problem the code is reporting, and the usual solution are listed in a
table at the end of this section.
Syntax Errors
The 3600 printer responds to syntax errors in the messages it receives from the
host by attempting to execute the commands. It does not ignore a command
with a syntax error. Instead, the printer produces output, even if it is
erroneous, which gives you an indication of what went wrong and what
should be done to correct the problem.
Parameter Errors
Certain commands require optional parameters. If these parameters are not
supplied, default values are substituted. If a parameter is above its maximum
range limit, the maximum value is used. If it falls below the minimum range,
the minimum value is used. The range and the default value for each command
are listed in Chapter 6 of the user's manual.
Image Overrun Errors
Image overrun occurs when a label is too complex to image for a given print
speed. An overrun will cause the printer to abort the label being printed. This
error is most common on labels over 5 inches long.
The printer automatically attempts to correct for this error condition by
resetting to the lowest print speed and to the highest number of image bands,
and then repeats printing the label. The printer remains at this setting until you
reset it. If an image overrun still occurs, printing for that batch of labels stops
and any following commands are executed.
Installing the optional 512K memory expansion prevents image overrun errors.
4-5
3600 Printer Maintenance Manual
Invalid Numeric Character Errors
If non-numeric characters are included within a numeric data string in a
command, the printer disregards them and continues to process the rest of the
valid numeric characters. However, if a non-numeric character begins the
numeric data string, the printer uses a default value for the affected command.
Here are two examples of valid numeric character strings and one example of
an invalid string:
12a valid
la2 valid
al2 invalid
Insufficient Storage RAM Errors
Before storing new formats, graphics, or user-defined fonts in the static RAM,
the printer checks to see if it has sufficient memory to store them. If there is
insufficient memory, the last editing session is disregarded. The printer is
designed to preserve the integrity of the existing data in the static RAM.
Error Codes
Most of the problems you may encounter cause the 3600 printer to send an
error code to the host. When this happens, find the error code in the following
table and try the solution given to attempt to correct the problem.
4-6
Troubleshooting
Printer Errors
Error Code Problem
00 No error.
01 Invalid bar code check character.
02
04
05
06
07
08
11
12
13
21
22
23
24
25
26
27
28
Invalid number of bar code
characters (Code UPC/EAN).
Bar code check character within
numeric field marks.
Supplemental delimiter within
numeric field marks (Code
UPC/EAN).
Invalid supplemental character
count (UPC/EAN).
More than one supplemental
delimiter (Code UPC/EAN).
Invalid start /stop characters
(Codabar).
Invalid bar code data.
Data count exceeded.
Entering data in non-data entry field.
Quantity or batch count out of range.
Field increment/ decrement out of
range.
Intercharacter/ message delay out of
range.
Missing preamble/postamble data.
Invalid format transmission syntax.
Invalid page transmission syntax.
Invalid font transmission syntax.
Invalid UDC transmission syntax.
Solution
Verify the bar code check character modifier used in the
bar code program command.
Verify the number of bar code characters used in the bar
code program command.
Check the bar code program command for accuracy.
Check the bar code program command for accuracy.
Check the bar code program command for accuracy.
Check the bar code program command for accuracy.
Verify start and stop characters in the label format.
Verify data in the label format.
Data count should not exceed what is specified for the
field.
Check the field for accuracy.
Quantity of labels or number of batches should be
between 1 and 9999.
Quantity should be between 1 and 9999.
Delay should be between and 9999.
Delete the setup for preamble or postamble data, or
include the data.
Check the format transmission syntax. The correct
syntax is <ESC>xjnj with n ranging from to 19.
Check the page transmission syntax. The correct syntax
is <ESC>y{n( with n ranging from to 9.
Check the font transmission syntax. The correct syntax
is <ESC>v{n| with n ranging from to 24.
Check the UDC transmission syntax. The correct syntax
is <ESC>u{n( with n ranging from to 99.
4-7
3600 Printer Maintenance Manual
Printer Errors (continued)
Error Code Problem
32
33
34
35
36
37
38
41
42
43
46
52
53
54
Non-immediate command or data
received after buffer full.
Invalid field delimiters.
Invalid escape command.
Invalid data shift command.
Invalid or undefined format
number.
Insufficient room in RAM to print
format.
Invalid or undefined field number.
Syntax error for program
commands.
Insufficient room in RAM to store
format.
Too many fields in label format.
Undefined statement.
Invalid UDC/UDF bitmap cell
height/width or intercharacter
space.
Insufficient room in RAM to store
UDC or UDF.
Solution
Allow the printer to empty the buffer contents before
sending commands or data.
Check for all pairs of field delimiters, and make sure both
are numeric or both are alphanumeric.
Correct the escape command syntax.
Correct the shift command syntax.
Verify that the format numbers are between and 19.
Reduce the number of data fields in the format.
Verify the field number in the label format.
Check the program command for proper syntax.
Empty the buffer contents. If the format still does not fit,
delete some fields or other data from the format. You may
have to remove or reduce the UDCs, formats, or fonts if
necessary.
Note: Entering <ESC>m tells the host how much memory is
installed and how much is available.
You can use up to 200 fields in a format and each field can
use up to 250 characters. Reduce field size or delete some
fields.
Check the statement syntax.
Verify that cell heights and widths are between 1 and 599,
and that the intercharacter space is between and 199.
Remove or reduce formats, fonts, or UDCs.
Invalid UDC command syntax. Correct the UDC command syntax.
4-8
Troubleshooting
Printer Operation Problems
Symptom
No power or loss of
power.
Labels stop feeding
through the printer.
Printer slows down.
If a printer is not operating correctly, try locating the problem and
implementing the solution from the following table:
Labels stick to door or
fail to strip.
The stepper motor
stalls while printing
media that is less than
6.6 inches wide.
Configuration label
does not print.
Possible Causes
AC power cable is damaged or
disconnected.
Printer circuit breaker tripped.
Power supply function is failing.
Printer is out of media.
Solution
Make sure the power cable is plugged into both
the printer and an outlet or power strip. Replace
the cable if it is damaged.
Turn the printer off and then back on again
(determine why it tripped). Replace circuit
breaker if defective.
Check the transformer and the main PCB.
Replace whichever is defective.
Load new media.
Label stock is loaded incorrectly. Check the media path.
Media is sticking to the paper
path.
Printer is set for continuous label
stock.
Label sensor(s) dirty, out of
adjustment, or failing.
Image bands or print speed are
incorrectly set.
Printer has aborted and print
speed and image bands were
reset.
The self -strip roller is dirty or the
pinch roller is not contacting the
strip roller.
The bias is not adjusted properly.
Clean any extraneous material from the paper
path and clean it thoroughly.
Use the Transmit Configuration Parameters
<ESC>p command to check the configuration
setting. Select the correct setting with the Select
Label Stock Type command (<SI>T).
Clean and adjust, or replace the sensor(s) as
required.
Change the image bands or print speed settings.
Change the image bands or print speed settings.
Clean the self -strip roller.
Adjust the bias adjust screw to the optimum
printing position.
The media is loaded incorrectly. Try reloading the media.
4-9
3600 Printer Maintenance Manual
Print Quality Problems
If labels are not printing properly, try locating the problem and implementing
the solution in the following table:
Symptom
Blotches on labels.
Printing is too light or
too dark.
Printing not aligned
on label.
Labels are not
stopping at the right
point to be removed.
Possible Causes
Dirty printhead.
Dirty media path or rollers.
Poor quality label or ribbon
stock.
Darkness adjust control is set
incorrectly.
Poor quality label or ribbon
stock.
Sensitivity number is set
incorrectly.
Dirty printhead.
The printhead adjustment lever
is not positioned as needed.
Printer is misfeeding media.
Platen roller and/or printhead
out of alignment.
Label rest point command is
incorrectly set.
Printer is set for continuous label
stock.
Solution
Clean the printhead.
Clean the media path.
Use only Intermec label and ribbon stock to
ensure superior print quality and product
performance.
Adjust the knob to achieve the best print quality.
Use only Intermec label and ribbon stock to
ensure superior print quality and product
performance.
Change sensitivity setting to match the type of
media being used. If sensitivity is set correctly,
try changing the dark adjust command.
Clean the printhead.
Reposition the printhead adjustment lever.
Make sure that media is installed properly along
the entire media path.
Perform roller alignment first and then
printhead alignment.
Adjust the label rest point.
Set the printer for proper label stock; either gaps
or marks.
4-10
Troubleshooting
Symptom
Print quality is poor.
Possible Causes
Incorrect media sensitivity.
The darkness of label print is too
light or too dark.
Printhead, platen roller, or label
path are dirty.
Uneven print contrast (density).
Incorrect label or ribbon stock is
used to print labels.
Ribbon wrinkling.
Ribbon installed upside down.
Direct thermal /thermal transfer
switch set in the wrong position.
Printhead or platen roller is
severely worn.
Media may be slipping against
the platen roller causing the
printing to compress.
Solution
Change sensitivity setting to match the type of
media you are using. If sensitivity is set
correctly, try changing the dark adjust.
Properly set the darkness adjust control.
Clean printhead, platen roller, and label path.
Adjust the bias adjust screw.
Use only Intermec label and ribbon stock to
ensure superior print quality and product
performance.
Check to make sure that the ribbon is installed
correctly.
Check the following alignments in the sequence
given, testing for elimination of the problem
before performing the next alignment.
Note: Making these adjustments out of order can
introduce and not solve printing problems.
1) Roller alignment
2) Printhead alignment
3) Ribbon supply hub alignment
Install ribbon with shiny side facing the
printhead.
Set the switch for the type of media being used.
Replace the platen roller or printhead.
Switch to approved media or clean the
printhead and platen.
4-11
3600 Printer Maintenance Manual
Communications Problems
If a printer is not receiving downloaded data, consider the causes and solutions
in this section.
Symptom
Printer does not
communicate with the
host.
Possible Causes
Serial port is incorrectly
configured.
Disconnected, damaged, or
incorrect I/O cable.
Solution
Make sure the printer's serial port settings
match those of the host. Print a software test
configuration label to check the serial port
settings.
Check the connections at both ends. Replace the
cable if necessary.
Any loss of data can cause printing errors or missing data. The 3600 printer is a
serial ASCII device that communicates with the host through an ASCII serial
communications port. The two devices communicate through the use of
hardware and software protocols (handshaking). The printer utilizes both
forms of handshaking simultaneously when the printer's input buffer is full.
Consider this process when troubleshooting.
Hardware handshaking uses pins 11 or 20 of the RS-232 interface to control
data flow. When the printer is using Intermec "Standard" protocol, pin 11 and
20 are held high when the printer is ready to receive data. The pins are held
low when the printer is in one of the following conditions:
• Buffer full
• Ribbon fault
• No label stock
• Label at strip pin
The 3600 printer uses XON/XOFF protocol for software handshaking. When
the input buffer is full, the printer transmits an XOFF character. This character
alerts the host to the fact that the printer buffer is full and cannot receive any
more data. When the printer is ready to receive more data, it sends the XON
character.
4-12
Troubleshooting
To check for communications problems
1 . Check the cabling from the printer to the host system.
2. Check the interfacing of the devices that are communicating with the
printer.
3. Check the printer for proper electrical operation of the serial
communications port.
4. Test to see that the host system is not overrunning the printer's input
buffers.
5. Check to see that the data string being sent to the printer contains the
correct information.
Environmental Problems
Symptoms associated with environmental problems are printing garbage,
resetting, or total lockup. One way to discover if the problem is environmental
is to see if the problem goes away when the printer is moved to a new location.
If it shows up in a printer recently moved from another area, the problem is
probably environmental. The following is a discussion of different types of
environmental problems.
Electrostatic Discharge (ESD)
ESD can cause failure or weakening of affected components. Typically, ESD
occurs when a person with a large electrical potential unintentionally
discharges that potential by touching the conductive surfaces of the equipment.
Static charge is created through friction from people walking, conveyor belts,
paper moving through a printer, and wheelchairs. The solution is to reduce the
charge by grounding and by employing prevention measures such as antistatic
bags for ICs and PCBs, grounded antistatic mats, antistatic spray for carpeting,
antistatic clothing (no wool), antistatic wax for tile floors, conductive floor
materials, air ionizers, and antistatic cleaners for plastics. To further protect
against ESD, use shielded cable for interface cables, and tie the shield to metal
backshells at both ends of the cable. Do not connect the shield of the cable to
the chassis ground or signal ground of the interface (metal backshells will be
tied to the chassis).
4-13
3600 Printer Maintenance Manual
Electromagnetic and Radio Frequency Interference
Noise induced in interface cables can result in the printer receiving false data.
This condition may cause the printer to skip printing a label or lockup. Sources
of electromagnetic interference (EMI) and radio frequency interference (RFI) are
radio transmitters, ignition systems, and relays. To eliminate the effects of EMI
and RFI, use low capacitance, twisted pair, shielded cables. Route cables away
from sources of EMI and RFI such as large inductive motors or fluorescent
lighting ballasts. Do not run cables near AC power lines. If communication
cables must run near AC power lines, cross them at 90 degree angles. Eliminate
ground loops; they act as receiving antennas for RFI. Limit the number of
breaks (connectors) in the cable. It is possible to use a power line monitor, such
as the BMI 4800, to test for noise on the interface cable.
Ground Loops Between Equipment
Ground loops pick up RFI as well as generate their own noise in interface
cables. The recommended wiring of the interface cable calls for connecting
chassis ground (pin 1) between the host computer and the printer to ensure
that the chassis of both devices remains at the same electrical potential in the
event of a faulty ground in either device. This safety precaution will save
people from electric shock in the situation where they touch both the host
computer and the printer at the same time while there is a faulty ground in
either device. With this wiring, you would normally expect problems with
ground loops, but the printer, chassis ground, and signal ground are connected
to each other through a lOkQ. resistor, thus providing some ground loop
immunity.
If connections in the interface cable described above are discovered to cause
ground loop problems, disconnect the shield from the backshell at only the
printer, and sever the chassis ground (pin 1) connection between the host
computer and the printer. To ensure safety, double your efforts to guarantee
that both the host computer and the printer make a solid electrical and physical
connection to earth ground.
Inadequate Earth Ground
Poor grounds can cause fuses on equipment to blow and damage components.
The ground in the AC power receptacle must be a good, solid earth ground. Do
not rely on conduit for ground. The ground rod should penetrate the earth at
least 8 feet below the frost line. The soil should contain clay minerals; dry,
sandy soil does not provide a good ground. Ensure that all ground connections
from the service panel to the AC receptacle are solid and secure.
4-14
Troubleshooting
AC Power Problems (Surges, Sags, Spikes, Noise, and Outages)
Most environmental problems involve the AC power line. In the 3600 printer,
115V supply voltages can range from 90 to 132 VAC. Outside the U.S., 230V
supply voltages can range from 180 to 264 VAC. Voltage overages or
underages can result from poor utility regulation to in-plant loading of the
power service. Use a power line monitor, such as the BMI 4800, to look for
power service problems. To eliminate the effects of voltage overages and
underages, install an uninterruptible power supply (UPS) or install a dedicated
circuit for the printer and the host computer.
Intermittent power outages can be caused by a combination of vibration and
loose connections between the service panel and the AC receptacle. Check the
wiring to ensure that all connections are solid and secure. Use a power line
monitor to test for outages. To eliminate the effects of power outages, install a
UPS.
Impulse noise on the power line can also cause the printer to lockup or reset.
All Intermec products, including the 3600 printer, meet IEC 801, Surge and
Burst specifications. Impulses can range from 200 to 5000V and are caused by
lightning, switching operations, firing of SCRs, triacs, static discharge, and arc
welders. Use a power line monitor to verify the presence of impulse noise, and
use a spike suppressor to eliminate its effect.
Irregular sine waveforms on the AC power line can also affect printer
performance. They are caused by switching power supplies. Use a power line
monitor to verify the presence of irregular sine waveforms and use a power
line conditioner to eliminate their effects.
High frequency noise and hash riding on the AC waveform can affect printer
performance. They are caused by transmitters and ignition systems. Use an
oscilloscope to verify the presence of noise and hash. Install EMI/RFI filters to
eliminate their effects.
To troubleshoot environmental problems
1 . Correlate an environmental event with the failure.
2. Check for static discharges.
3. Check for adequate grounding.
4. Check the AC power for proper level and purity.
5. Check for inductive motors, relays, or other spike inducing equipment on
the power line.
6. Exercise good judgment and common sense.
4-75
3600 Printer Maintenance Manual
Miscellaneous Problems
The following information identifies some possible printer problems and what
might be their cause.
• Problems with printer-to-computer communications, motor control, or
media advance may be caused by a faulty main PCB assembly.
• If information downloaded to the printer memory is lost after the printer is
powered off (lost data includes configuration setting changes reverting to
their factory defaults when power is cycled), the lithium battery may be
bad.
• The appearance of long white streaks in printed labels indicates a dirty
printhead or possible printhead failure.
• If you have problems with the bezel LEDs or the Feed/Pause button, you
may need to replace the bezel PCB assembly.
• If the printer no longer registers the use of marked label stock, you may
need to replace the label mark sensor.
• Light print on one side of a label can occur if the printhead is not making
even contact with the media. This condition can happen with any size
media, but is most common when using narrow labels where there is no
media between the printhead and the platen roller. Uneven lateral print
darkness may be eliminated by adjusting the bias screw.
If the printer is no longer sensing when labels have been removed, you may
need to adjust or replace the label taken sensor.
If the TTR takeup hub fails to roll up ribbon, you may need to replace the
upper drive belt and/or the TTR takeup clutch.
If a ribbon fault occurs when the printer is in the TTR mode, you may need
to replace the TTR encoder sensor.
If the liner takeup hub discontinues rolling up liner, you may need to
replace the liner takeup (lower) drive belt or clutch.
If the platen roller does not turn but the liner drive roller does, you may
need to replace the platen roller gear.
If none of the rollers turn, you may need to replace the stepper motor.
4-16
Remove and Replace Procedures
Remove and Replace Procedures
This chapter contains illustrated instructions for removing and replacing key
components of the 3600 printer.
Replacing Printer Components
When a printer component needs replacing, use the appropriate following
procedure. See Chapter 7, "Replacement Parts," for a complete list of spare
parts.
After replacing a component, refer to Chapters 2 and 3 for the procedures to
complete the repair by ensuring that you leave the printer performing at its
optimum level.
Prior to taking any action, review all warnings, cautions, and procedures
associated with any component you intend to remove.
When performing any of the procedures in this chapter, heed the following
warnings and cautions at all times to avoid the consequence identified.
A Warning
Always disconnect the power cord before removing the electronics
WARNING cover unless the procedure requires the unit be energized. Failure to
disconnect the power cord may result in injury or death due to
electric shock.
Caution
The printhead and integrated circuits on printer circuit boards in
CAUTION ^is equipment are sensitive to damage by electrostatic discharge
(ESD). Prevent ESD by always wearing skin contact ground straps
firmly attached to the equipment metal base assembly when
working inside of the equipment housing. Failure to comply can
result in damage to components or the printhead.
Caution
Do not remove the motor plate or subplates. Changing the position
CAUTION of the motor plate can alter factory alignment and cause ribbon
wrinkling or liner-stripping problems.
5-3
3600 Printer Maintenance Manual
Replacing the Lithium Battery
To replace the lithium battery, you will need the following parts and tools:
• 1.75AH 3.6V AA lithium battery, Intermec Part No. 586229
• ESD grounding strap
• #2 Phillips screwdriver
A
WARNING
Warning
There is danger of explosion if the battery is incorrectly replaced. Replace
it only with the same or equivalent type battery recommended by the
manufacturer. Discard used batteries according to the manufacturer's
instructions.
II y a danger d 'explosion s'il y a remplacement incorrect de la batterie.
Remplacer uniquement avec une batterie du meme type ou d'un type
recommande par le constructeur. Mettre au rebut les batteries usagees
conformement aux instructions du fabricant.
To replace the lithium battery
Note: The printer will lose data if the battery fails or is removed. Before removing the
battery, upload and save the fonts, formats, pages, graphics, and configuration settings.
1 . Switch off the printer power and remove the power cord, the media cover,
and the electronics cover.
2. Remove the old battery and install the new battery, matching the (+) and (-)
ends of the battery with the (+) and (-) signs on the main PCB.
Lithium
battery
3. Install the covers and power cord. Check the printer for proper operation.
5-4
Remove and Replace Procedures
Replacing the Printhead
To replace the printhead, you will need the following parts and tools:
• 6.6-inch 5 mil printhead, Intermec Part No. 061611S-001
• ESD grounding strap
• Medium straight-slot screwdriver
To replace the printhead
1 . Switch off the printer power and remove the power cord.
2. Remove the media cover.
3. Raise the printhead. Remove media and ribbon if loaded.
4. Release the locks on the printhead cable by pressing in on each side of the
cable connector. Remove the printhead cable.
Note: If you need slack to separate the printhead and cable, unplug the cable from
the main PCB and pull some of it through the cutout in the main deck plate.
Printhead
retaining
screw
Straight slot
screwdriver
Cable
connector
Printhead
cable
Printhead
5-5
3600 Printer Maintenance Manual
5. Use a straight-slot screwdriver to loosen the printhead retaining screws,
located in the center of the printhead heatsink. The screw is easier to loosen
if you place one of your fingers underneath the printhead, between the
printhead and the platen roller. Pull the printhead away from the printer
(since it is a tight fit, you may need to pull it out from the outboard side
rather than from the front).
6. Replace the printhead and cable and tighten the printhead retaining screws.
7. Reload media (and ribbon if used) and lower the printhead.
8. Install the media cover and the power cord and check the printer for proper
operation.
Replacing the Bezel PCB
To replace the bezel PCB, you will need the following parts and tools:
• Bezel PCB assembly, Intermec Part No. 059052S-001
• ESD grounding strap
• #1 and #2 Phillips screwdrivers
To replace the bezel PCB assembly
1 . Switch off the printer power and remove the power cord.
2. Remove the media cover and the electronics cover.
3. Unplug the bezel PCB assembly from the main PCB and remove the five
screws that hold the front bezel cover to the printer.
Front bezel
cover
5-6
Remove and Replace Procedures
4. Lift the front bezel cover away from the printer and lay it on a flat surface.
5. Use the #2 Phillips screwdriver to remove the two screws that hold the
bezel PCB/ cover plate assembly to the front bezel cover.
6. Being careful not to break the switch stem or the button cap, pull the
Feed/Pause button cap off of the switch on the bezel PCB. Retain the
yellow button cap for installation onto the replacement bezel PCB.
7. Use the #1 Phillips screwdriver to remove the two screws securing the bezel
PCB to the front cover plate.
Bezel PCB
assembly
Yellow
button
cap
Front cover
plate
Front bezel
cover
8. Use the #1 Phillips screwdriver to attach the replacement bezel PCB to the
front cover plate.
9. Carefully press the yellow button cap removed in Step 6 onto the switch on
the replacement bezel PCB.
10. Attach the bezel PCB front cover plate assembly to the front bezel cover.
11. Reattach the front bezel cover to the printer. Ensure that the media access
door operates properly (snaps firmly shut) after the front bezel cover is
installed. Connect the cable.
12. Install the electronics cover, the media cover, and the power cord, and
check the printer for proper operation.
5-7
3600 Printer Maintenance Manual
Replacing the Main PCB
To replace the main PCB, you will need the following parts and tools:
• 3600 main PCB assembly, Intermec Part No. 061591S-005 or 06159E-005
• ESD grounding strap
• #2 Phillips screwdriver
To replace the main PCB assembly
1. Switch off the printer power and remove the power cord, the media cover,
and the electronics cover.
2. Unplug all of the cables from the main PCB and remove the seven screws
securing the main PCB to the printer to remove the main PCB. Do not place
the printer on its side as this may disturb alignments.
Main PCB
assembly
3. If the main PCB you are replacing has the 512K SRAM memory expansion
chip, verify that the new main PCB is similarly equipped. If it is not,
carefully unplug the existing 512K chip and plug it into the new main PCB
before installing it.
4. If the main PCB you are replacing has a Kanji/Katakana option PCB
installed, use the next procedure to relocate the Kanji/Katakana option PCB
to the new main PCB before installing it.
5. Install the new main PCB, securing it with the seven screws removed in
Step 3, and connect all of the cables.
6. Install the electronics cover, the media cover, and the power cord, and
check the printer for proper operation.
5-8
Remove and Replace Procedures
Replacing the Kanji/Katakana Option PCB
To replace a Kanji/Katakana PCB, you will need the following parts and tools:
• 3600 Kanji/Katakana PCB, bitmap font, Intermec Part No. 060689-001 or
3600 Kanji/Katakana PCB, outline font, Intermec Part No. 060690-001
• ESD grounding strap
• #2 Phillips screwdriver
To replace the Kanji/Katakana PCB
1 . Switch off the printer power and remove the power cord, the media cover,
and the electronics cover.
2. Remove the screws that secure the Kanji/Katakana PCB to the main PCB.
PCB stacking
spacer
Kanji/Katakana PCB
3600M.047
5-9
3600 Printer Maintenance Manual
3. Unplug the Kanji/Katakana PCB from the main PCB using a gentle rocking
motion while pulling it away.
4. Install the new Kanji/Katakana PCB onto the main PCB, making sure the
pins are properly aligned with the connector and that the Kanji/Katakana
PCB is fully seated before tightening the screws.
5. Install the electronics cover, the media cover, and the power cord, and
check the printer for proper operation.
Replacing the Label Mark Sensor
To replace the label mark sensor, you will need the following parts and tools:
• Label mark sensor cable assembly, Intermec Part No. 061578-001
• Roller alignment tool, Intermec Part No. T43150
• ESD grounding strap
• #1 and #2 Phillips screwdriver
To replace the label mark sensor
1 . Switch off the printer power and remove the power cord.
2. Remove the media cover, the electronics cover, and the front bezel cover
(refer to "Replacing the Bezel PCB" earlier in this chapter).
3. Raise the printhead. Remove media and ribbon if loaded.
4. Remove the screws securing the lower outboard plate to the printer and
pull it away from the printer. Retain the tear bar and tear bar support.
Tear bar
Tear bar
support
Lower outboard
plate
3600M.048
5-10
Remove and Replace Procedures
Disconnect the label mark sensor cable from the main PCB, remove the
cable from the two plastic clips, and push it through the cutout in the main
deck plate. Slide the sensor out from the extrusion. Remove the cable from
the plastic cable clip on the extrusion.
Label mark
sensor
6. Insert the new label mark sensor into the extrusion. Route the cable
through the plastic cable clip on the extrusion and through the cutout in the
main deck plate, and then plug it into the main PCB. Secure the cable in
place by inserting it into the two cable clips. Any slack in the cable should
be arranged between the sensor and the cable clip on the extrusion. There
should be no slack cable on the electronics side of the printer. Make sure
the cable is secure and not contacting any moving parts.
7. Reassemble the tear bar and bar support and install the lower outboard
plate, capturing the tear bar, liner drive roller, and platen roller.
Note: Use the roller alignment tool during reassembly for proper alignment of the
outboard plate.
8. Reattach the front bezel cover. Ensure that the media access door operates
properly (snaps firmly shut) after the front bezel cover is installed.
9. Reload media (and ribbon if used) and lower the printhead.
10. Install the electronics cover, the media cover, and the power cord, and
check the printer for proper operation.
5-11
3600 Printer Maintenance Manual
Replacing the Label Taken Sensor
To replace the label taken sensor, you will need the following parts and tools:
• Label taken sensor cable assembly, Intermec Part No. 059496-002
• ESD grounding strap
• #1 and #2 Phillips screwdriver
To replace the label taken sensor
1 . Switch off the printer power and remove the power cord.
Remove the media cover, the electronics cover, and the front bezel cover
2.
3.
4.
(refer to "Replacing the Bezel PCB" earlier in this chapter).
Raise the printhead. Remove media and ribbon if loaded.
Disconnect the label taken sensor cable from the main PCB, remove the
cable from the two plastic clips, and push it through the cutout in the main
deck plate. Slide the sensor housing away from the main deck plate.
Main
deck
plate
Label taken
sensor
Install the new sensor, routing the cable through the cutout in the main
deck plate and plugging it into the main PCB. Place the cable in the plastic
clips with the black sleeve positioned as close as possible to the sensor end.
Reattach the front bezel cover. Ensure that the media access door operates
properly (snaps firmly shut) after the front bezel cover is installed.
Reload media (and ribbon if used) and lower the printhead.
Install the electronics cover, the media cover, and the power cord, and
check the printer for proper operation.
5-12
Remove and Replace Procedures
Replacing the Label Gap Sensor
To replace the label gap sensor, you will need the following parts and tools:
• Label gap cable assembly, Intermec Part No. 059495-001
• ESD grounding strap
• Small straight-slot screwdriver
• 12-inch shank #2 Phillips screwdriver
To replace the label gap sensor
1. Switch off the printer power and remove the power cord, the media cover
and the electronics cover.
2. Raise the printhead. Remove media and ribbon if loaded.
3. Disconnect the label gap sensor cable from the main PCB.
Upper and lower
media guide assembly
Gap sensor
cable
Label gap
sensor ^
#1
3600M.051
4. Remove the three screws securing the upper/lower media guide assembly
to the main deck plate.
5. Slide the upper media guide outward to separate it from the rest of the
assembly.
5-13
3600 Printer Maintenance Manual
Upper
media
guide
Label gap
sensor
housing
Lift spring
6. Use a small straight-slot screwdriver to lift up on each of the two molded
tabs that secure the label gap sensor. Slide the label gap sensor from its
housing and replace it with the new label gap sensor. The label gap sensor
should snap into place.
7. Slide the upper media guide plate back together with the lower media
guide plate.
8. Route the label gap sensor cable through the cutout in the main deck plate
and reattach the media guide assembly to the frame. Be sure that the media
brake arm does not rub on the upper media guide and that the sensor cable
is not contacting any moving parts.
9. Attach the label gap sensor cable to the main PCB.
10. Reload media (and ribbon if used) and lower the printhead.
11. Install the electronics cover, the media cover, and the power cord, and
check the printer for proper operation.
5-14
Remove and Replace Procedures
Replacing the TTR Drive Roller and Gear/Pulley
To replace the TTR drive roller or the TTR drive gear/pulley or both, you will
need some or all of the following parts and tools:
• TTR drive roller, Intermec Part No. 061543-002
• TTR drive gear/pulley, Intermec Part No. 061563-002 (white)
• Retaining E-rings, Intermec Part No. 501401
• Retaining snap ring, Intermec Part No. 501409
• Roller alignment tool, Intermec Part No. T43150
• ESD grounding strap
• Snap ring pliers
• Needlenose pliers
• #1 and #2 Phillips screwdriver
To remove the TTR drive roller and TTR drive gear/pulley
1 . Switch off the printer power and remove the power cord.
2. Remove the media cover, the electronics cover, and the front bezel cover
(refer to "Replacing the Bezel PCB" earlier in this chapter).
3. Raise the printhead. Remove media and ribbon if loaded.
4. Unloop the drive belt (O-ring) from the TTR drive gear/pulley.
TTRtakeup ^ /£
drive belt y /r! "-
TTR drive
roller
x Motor
plate
j^WI Washer
Washer
E-ring
5-15
3600 Printer Maintenance Manual
Remove the TTR drive gear/pulley retaining E-ring. Retain the washer
located between the E-ring and the TTR drive gear/pulley. Discard the old
E-ring.
Remove the retaining snap ring that secures the printhead lift lever to the
cam assembly shaft. Pull the printhead lift lever off of the printhead lift
shaft. Discard the old snap ring.
Washer E-ring
Washer
TTR drive
' roller
E-ring \
Cam assembly
shaft
Printhead
spring
, Snap ring
lever r a
Unhook the printhead spring from the upper outboard plate and remove
the screws securing the plate to the printer. Pull the plate away, freeing up
the TTR drive roller (and the TTR shaft, printhead pressure cam assembly,
and pivot block).
Remove the TTR drive roller, sliding the gear /pulley off of the roller shaft.
Retain the washer located between the roller and the main deck plate and
the washer located between the gear/pulley and the main deck plate.
You can now replace either the TTR drive roller, the TTR drive gear/pulley,
or both.
5-16
Remove and Replace Procedures
To replace the TTR drive roller and TTR drive gear/pulley
1. Position the TTR drive gear /pulley with the correct washer installed
between the gear/pulley and the main deck plate.
2. Insert the TTR drive roller with a new retaining E-ring and the other
washer through the main deck plate and into the gear /pulley.
3. Install the upper outboard plate, making sure that the printhead spring is
in place on the pivot block and that all four shafts are securely inserted into
their correct positions in the plate.
Note: Use the roller alignment tool during reassembly for proper alignment of the
outboard plate.
4. Hook the printhead spring around the upper plate.
5. Install the printhead lift lever and secure it with a new retaining snap ring.
6. Secure the TTR drive gear/pulley on the roller shaft with a new retaining
E-ring and the washer you removed in Step 5.
7. Fit the loose end of the TTR drive belt over the TTR drive gear/pulley.
8. Reattach the front bezel cover. Ensure that the media access door operates
properly (snaps firmly shut) after the front bezel cover is installed.
9. Reload media (and ribbon if used) and lower the printhead.
10. Install the electronics cover, the media cover, and the power cord, and
check the printer for proper operation.
5-77
3600 Printer Maintenance Manual
Replacing the TTR Takeup Hub, Clutch/Pulley, and Belt
To replace the TTR takeup hub, TTR takeup clutch/pulley, and TTR takeup
drive, you will need some or all of the following parts and tools:
• TTR takeup hub, Intermec Part No. 061562-005
• TTR takeup clutch assembly, Intermec Part No. 062927S-001 (white)
• 2.800ID x .210 drive belt (O-ring), Intermec Part No. 501462-003
• Retaining snap rings, Intermec Part No. 501410
• ESD grounding strap
• Snap ring pliers
• #1 and #2 Phillips screwdriver
To remove the TTR takeup hub, TTR takeup clutch/pulley, and TTR drive belt
1 . Switch off the printer power and remove the power cord.
2. Remove the media supply cover, the electronics cover, and the front bezel
cover (refer to "Replacing the Bezel PCB" earlier in this chapter).
3. Raise the printhead. Remove media and ribbon if loaded.
4. Remove the two TTR takeup clutch/pulley retaining snap rings and the
thick washer from the end of the TTR takeup hub shaft. Retain the washer.
Discard the old snap rings.
TTR takeup
drive belt
TTR clutch/
■"pulley
Thick
washer
Snap ring
TTR takeup
hub
TTR drive
gear/pulley
5-18
Remove and Replace Procedures
5. Pull out on the TTR takeup hub to release the clutch/pulley assembly.
Retain the thin washer located between the TTR takeup hub and main deck
plate.
6. Remove the TTR takeup clutch/pulley assembly and TTR drive belt.
Note: Do not remove the motor plate or subplates. Changing the position of these
plates can alter factory alignment and cause ribbon wrinkling or self-strip
problems.
7. Replace the TTR takeup hub, the TTR takeup clutch/pulley assembly, the
TTR drive belt, or any combination of them now.
To replace the TTR takeup hub, TTR takeup clutch/pulley, and TTR drive belt
1. Wrap the TTR drive belt around the TTR takeup clutch/pulley, positioning
the assembly so that the TTR takeup hub shaft can be inserted into the
clutch/pulley.
2. Install the TTR takeup hub with the thin washer removed in Step 5 above.
3. Install the thick washer removed in Step 4 and the two new retaining snap
rings to secure the TTR takeup components in place.
4. Loop the loose end of the TTR drive belt around the TTR drive gear\pulley.
5. Reattach the front bezel cover. Ensure that the media access door operates
properly (snaps firmly shut) after the front bezel cover is installed.
6. Reload media (and ribbon if used) and lower the printhead.
7. Install the electronics cover and the media cover.
8. Install the power cord and check the printer for proper operation.
5-19
3600 Printer Maintenance Manual
Replacing the TTR Supply Hub and Adjusting Plate
To replace the TTR supply hub, the TTR supply hub adjusting plate, or both
parts, you will need some or all of the following parts and tools:
• TTR supply hub, Intermec Part No. 061562-004
• TTR supply hub adjusting plate, Intermec Part No. 062603-001
• Retaining snap rings, Intermec Part No. 501410
• Ribbon supply hub alignment tool, Intermec Part No. T43149
• ESD grounding strap
• Snap ring pliers
• #1 and #2 Phillips screwdriver
To remove the TTR supply hub and TTR supply hub adjusting plate
1 . Switch off the printer power and remove the power cord.
2. Remove the media cover, the electronics cover, and the front bezel cover
(refer to "Replacing the Bezel PCB" earlier in this chapter).
3. Raise the printhead. Remove media and ribbon if loaded.
4. Remove the two retaining snap rings and thin washer from the electronics
side of the TTR supply hub shaft as shown on the next page. Retain the
washer. Discard the old snap rings.
5. Pull the TTR supply hub away from the printer and remove the TTR
supply clutch /encoder assembly. Retain the TTR supply clutch /encoder
assembly (this assembly is not a spare part), the nylon washer, and the
thick steel washer.
6. You can replace the TTR supply hub and TTR supply hub adjusting plate
now.
5-20
Remove and Replace Procedures
To replace the TTR supply hub and TTR supply hub adjusting plate
1 . Remove the two Phillips screws securing the TTR supply hub adjusting
plate to the TTR subplate and install the new adjusting plate in its place.
2. Install the thick steel washer removed in Step 5 above. Align the TTR clutch
encoder with the opening in the main deck plate and slide the TTR supply
hub back through the TTR clutch/encoder, the nylon washer, the motor
plate, and the TTR subplate.
Note: Do not remove the motor plate or subplates. Changing the position of these
plates can alter factory alignment and cause ribbon wrinkling or self-strip
problems.
Thick
Nylon w ^sher
washer TTR clutch/ j
encoder
Thin
washer
Snap ring
3. Install the thin washer removed in Step 4 and the new retaining snap rings.
4. Reattach the front bezel cover. Ensure that the media access door operates
properly (snaps firmly shut) after the front bezel cover is installed.
5. Align the ribbon supply hub as described in "Aligning the TTR Supply
Hub" in Chapter 3.
6. Reload media (and ribbon if used) and lower the printhead.
7. Install the electronics cover, the media cover, and the power cord, and
check the printer for proper operation.
5-21
3600 Printer Maintenance Manual
Replacing the Platen Roller and Gear
The platen roller and platen roller gear can be replaced separately or at the
same time. To replace the platen roller, the platen roller gear, or both parts, you
will need some or all of the following parts and tools:
• Platen roller, Intermec Part No. 061542-003
• Retaining E-ring, Intermec Part No. 501401
• Platen roller gear, Intermec Part No. 061557-003
• Retaining snap ring, Intermec Part No. 501409
• Roller alignment tool, Intermec Part No. T43150
• ESD grounding strap
• #2 Phillips screwdriver
• Needlenose pliers
• Snap ring pliers
To remove the platen roller and platen roller gear
1 . Switch off the printer power and remove the power cord.
2. Remove the media cover, the electronics cover, and the front bezel cover
(refer to "Replacing the Bezel PCB" earlier in this chapter).
3. Raise the printhead. Remove media and ribbon if loaded.
4. Remove the retaining snap ring that holds the platen roller gear in place as
shown on the next page. Retain the washer between the gear and the main
deck plate. Discard the old snap ring.
5. Remove the five screws that secure the lower outboard plate to the main
deck plate and pull the plate away from the rollers. The tear bar and tear
bar support come loose when the outboard plate is removed. Retain them
for reassembly.
Note: Now is a convenient time to replace the liner drive roller and liner drive
gear/pulley as instructed in the next procedure.
6. Remove the platen roller and washer. Retain the washer.
7. The platen roller, the drive gear, or both parts can be replaced now.
5-22
Remove and Replace Procedures
Platen
roller
gear
Tear bar
Snap
ring
Tear bar
support
To replace the platen roller and platen roller gear
1 . Loosen the motor as necessary to mesh the platen roller gear with the
motor pinion gear and TTR drive gear/pulley upon reassembly.
2. Install the washer removed in Step 6 and a new retaining E-ring on the
platen roller and insert it through the main deck plate and into the washer
removed in Step 4 and the platen drive gear.
3. Reassemble the tear bar and bar support, and then install the lower
outboard plate, securing the tear bar assembly and the rollers.
Note: Use the roller alignment tool during reassembly to align the outboard plate.
4. Secure the platen drive gear with a new retaining ring and slide the motor
forward to mesh the motor pinion gear with the platen drive gear and the
liner drive gear/pulley. Turn the TTR roller drive gear to check for proper
gear engagement and tighten the motor mounting screws.
5. Reattach the front bezel cover. Ensure that the media access door operates
properly (snaps firmly shut) after the front bezel cover is installed.
6. Reload media (and ribbon if used) and lower the printhead.
7. Install the electronics cover, the media cover, and the power cord, and
check the printer for proper operation.
5-23
3600 Printer Maintenance Manual
Replacing the Liner Drive and Takeup Components
To replace any combination of the liner takeup hub, liner reverse gears, liner
drive roller, liner takeup clutch /pulley, liner reverse shaft, liner drive
gear/pulley, and liner drive belt, you will need some or all of the following
parts and tools:
• Liner takeup hub, Intermec Part No. 061562-005
• Liner drive roller, Intermec Part No. 061568-002
• Liner reverse gears 1 and 2, Intermec Part No. 061588-002
• Liner takeup clutch/pulley, Intermec Part No. 061574S-001 (black)
• Liner reverse shaft, Intermec Part No. 061589-001
• 2.800ID x .210 drive belt (O-ring), Intermec Part No. 501462-003
• Liner drive gear/pulley, Intermec Part No. 061569-002 (black)
• Retaining E-rings, Intermec Part No. 501401
• Retaining snap rings, Intermec Part No. 501410
• Roller alignment tool, Intermec Part No. T43150
• ESD grounding strap
• #1 and #2 Phillips screwdriver
• Needlenose pliers
• Snap ring pliers
To replace the liner takeup hub and liner reverse gear 1
1 . Switch off the printer power and remove the power cord.
2. Remove the media cover, the electronics cover, and the front bezel cover
(refer to "Replacing the Bezel PCB" earlier in this chapter).
3. Raise the printhead. Remove media and ribbon if loaded.
4. Remove the retaining snap rings that hold the liner takeup hub and liner
reverse gear 1 in place as shown on the next page. Retain the washer
between the snap rings and the liner takeup subplate. Discard the old snap
rings.
5. Pull the liner takeup hub away from the main deck plate to remove it.
Retain the thick washer between the liner takeup hub and the main deck
plate. Liner reverse gear 1 can now be removed from behind the liner
takeup subplate.
Note: Now is a good time to replace other liner drive and takeup components
according to the following procedures.
5-24
Remove and Replace Procedures
Liner drive
gear/pulley
5-25
3600 Printer Maintenance Manual
6. You can replace the liner takeup hub and/or liner reverse gear 1 now.
7. Install the thick washer removed in Step 5 between the liner takeup hub
and the main deck plate. Position liner reverse gear 1 between the motor
plate and the liner takeup subplate and check for proper engagement with
liner reverse gear 2.
8. Insert the liner takeup hub through the main deck plate, reverse gear 1, and
the subplate. Install the washer removed in Step 4 on the hub shaft
extending through the subplate and secure with two new snap rings.
9. Reattach the front bezel cover. Ensure that the media access door operates
properly (snaps firmly shut) after the front bezel cover is installed.
10. Reload media (and ribbon if used) and lower the printhead.
11. Install the electronics cover, the media cover, and the power cord, and
check the printer for proper operation.
To replace the liner drive roller
1. If not already done, switch off the printer power and remove the power
cord, media cover, electronics cover, and the front bezel cover. Raise the
printhead and remove the media and ribbon if loaded.
2. Remove the five screws that secure the lower outboard plate to the main
deck plate and pull the plate away from the rollers. The tear bar and tear
bar support come loose when the outboard plate is removed. Retain them
for reassembly.
Snap
ring
Tear bar
Tear bar,
support
Liner drive Washer
gear/pulley
Lower
outboard
plate
Liner drive
roller
5-26
Remove and Replace Procedures
3. Remove the liner drive gear/pulley retaining E-ring. Retain the washer
located between the E-ring and the liner drive gear/pulley. Discard the old
E-ring.
4. Loosen the motor as necessary to disengage the pinion gear from the liner
drive gear/pulley to facilitate disassembly.
5. Remove the liner drive roller, sliding the liner drive gear /pulley off of the
roller shaft. Retain the washer between the roller and main deck plate. The
gear/pulley will remain trapped by the drive belt until the belt is removed
as described in the following procedure. Be sure to retain the washer
between the gear/pulley and the main deck plate when it comes loose.
Note: Now is a convenient time to replace other liner drive and takeup components
according to the following procedures.
6. You can replace the liner drive roller now.
7. Install the first washer you removed in Step 5 and a new retaining E-ring
on the liner drive roller shaft. Position the liner drive gear /pulley and the
second washer you removed in Step 5 between the motor plate and the
main deck plate. Then insert the liner drive roller through the main deck
plate into the washer and gear/pulley.
Note: The gear/pulley will be under some tension from the drive belt.
8. Reassemble the tear bar and bar support and install the lower outboard
plate, securing the tear bar assembly and the rollers.
Note: Use the roller alignment tool during reassembly for proper alignment of the
outboard plate.
9. Secure the liner drive gear/pulley with the washer removed in Step 3 and a
new retaining E-ring.
10. Slide the motor forward and mesh the motor pinion gear with the liner
drive gear/pulley and the platen roller gear. Turn the TTR roller drive gear
to check for proper gear engagement and tighten the motor mounting
screws.
11. Reattach the front bezel cover. Ensure that the media access door operates
properly (snaps firmly shut) after the front bezel cover is installed.
12. Reload media (and ribbon if used) and lower the printhead.
13. Install the electronics cover, the media cover, and the power cord, and
check the printer for proper operation.
5-27
3600 Printer Maintenance Manual
To replace liner reverse gear 2, the liner takeup clutch/pulley, liner reverse shaft,
liner drive gear/pulley, and liner drive belt
1 . If not already done, perform Steps 1 through 5 of the preceding liner roller
replacement procedure.
2. Remove the retaining snap ring that holds the liner reverse shaft, takeup
clutch/pulley, and reverse gear 2 in place. Retain the washer located
between the snap ring and subplate. Discard the old snap ring.
Liner takeup
clutch/pulley
assembly
Liner
reverse
shaft
Snap ring
Snap ring
. washer x reverse
-gear
5-28
Remove and Replace Procedures
3. Remove the liner takeup hub and reverse gear 1 as described in Steps 4 and
5 of that procedure (page 5-24).
4. Push the liner reverse shaft through the main deck plate, sliding off the
takeup clutch/pulley and reverse gear. Separate the drive belt from the
drive gear/pulley and clutch/pulley.
5. You can replace the liner drive gear/pulley, liner drive belt, takeup
clutch/pulley, liner reverse shaft, or reverse gear 2 now.
To reassemble the liner drive and takeup components
1 . Install the first washer you removed in Step 5 of the previous liner roller
replacement procedure and a new retaining E-ring on the liner drive roller
shaft. Loop the drive belt around the liner drive gear/pulley and position
the gear /pulley and the second washer you removed in Step 5, between the
motor plate and the main deck plate.
2. Insert the liner drive roller through the main deck plate into the washer and
gear/pulley. Secure the liner drive gear/pulley with a new retaining E-ring.
3. Reassemble the tear bar and bar support and install the lower outboard
plate, capturing the tear bar assembly and the rollers.
Note: Use the roller alignment tool during reassembly for proper alignment of the
outboard plate.
4. Fit the drive belt around the liner takeup clutch/pulley. Position the
clutch/pulley and reverse gear 2 between the subplate and motor plate
with the clutch/pulley located at the cutout in the motor plate.
Note: The clutch/pulley will be under some tension from the drive belt.
5. Insert the D-shaped end of the liner reverse shaft through outboard side of
the main deck plate, the takeup clutch /pulley, reverse gear 2, and the liner
takeup subplate. Install the washer removed in Step 2 and a new snap ring.
6. Install the liner takeup hub and liner reverse gear 1 as described in Steps 7
and 8 of that procedure.
7. Slide the motor forward and mesh the motor pinion gear with the liner
drive gear/pulley and the platen roller gear. Turn the TTR roller drive gear
to check for proper gear engagement and tighten the motor mounting
screws.
8. Reattach the front bezel cover. Ensure that the media access door operates
properly (snaps firmly shut) after the front bezel cover is installed.
9. Reload media (and ribbon if used) and lower the printhead.
10. Install the electronics cover, the media cover, and the power cord, and
check the printer for proper operation.
5-29
3600 Printer Maintenance Manual
Replacing the Stepper Motor
To replace the stepper motor, you will need the following parts and tools:
• Main stepper motor and cable assembly, Intermec Part No. 061551-002
• ESD grounding strap
• #2 Phillips screwdriver
To replace the stepper motor
1. Switch off the printer power and remove the power cord, the media cover,
and the electronics cover.
2. Unplug the motor cable from the main PCB and remove the motor from the
motor plate and motor mount bracket.
Screw
(3 places)
Stepper
motor
install
a screw in this
Motor mounting hole.
P late
3. Mount the new motor loosely to the motor plate with the cable positioned
at the bottom rear corner. Properly mesh the pinion gear with the platen
drive gear and the liner drive gear before tightening the screws completely.
4. Plug the motor cable into the main PCB. Check that the motor cable-to-
main PCB connection is correctly aligned before applying power to avoid
damaging the main PCB.
5. Install the electronics cover, the media cover, and the power cord, and
check the printer for proper operation.
5-30
Remove and Replace Procedures
Replacing the AC Plug/Input Filter
To replace the AC plug and input filter assembly, you will need the following
parts and tools:
• 3600 line AC plug and filter assembly, Intermec Part No. 060246-001
• ESD grounding strap
• #1 and #2 Phillips screwdriver
• Needlenose pliers
To replace the AC plug and input filter
1. Switch off the printer power and remove the power cord, the media cover,
and the electronics cover.
2. Disconnect the three push-on connectors attached to the back of the AC
plug/input filter assembly.
Push-on
connectors
AC power
plug & filter
(2 places)
3. Remove the two screws securing the AC plug/input filter assembly to the
main deck plate and remove the assembly.
4. Install the new AC power plug and input filter assembly and secure it with
the two screws removed in Step 3.
5. Reconnect the three push-on connectors removed in Step 2.
6. Install the electronics cover, the media cover, and the power cord, and
check the printer for proper operation.
5-31
3600 Printer Maintenance Manual
Replacing the Power Switch/Circuit Breaker
To replace the power switch and circuit breaker assembly, you will need the
following parts and tools:
Note: The 220-volt printer uses a 1 amp power switch/circuit breaker and the 115-volt
printer uses a 2 amp power switch/circuit breaker.
• AC power switch /circuit breaker, Intermec Part No. 501273-001 (2A) or
AC power switch /circuit breaker, Intermec Part No. 501273-002 (1A)
• ESD grounding strap
• Needlenose pliers
• #2 Phillips screwdriver
To replace the power switch/circuit breaker
1 . Switch off the printer power and remove the power cord.
2. Remove the media cover and the electronics cover.
3. Disconnect the two leads with push-on connectors attached to the power
switch.
Rear
panel ~
Tabs ^
Power switch/
circuit breaker
Transformer lead
AC power plug lead
5-32
Remove and Replace Procedures
4. Compress the tabs that hold the power switch secured to the back plate and
push it out of the main deck plate.
5. Install the power switch by pushing the new receptacle into the cutout in
the main deck plate.
6. Reattach the two push-on connectors removed in Step 3.
7. Install the electronics cover, the media cover, and the power cord, and
check the printer for proper operation.
Replacing the Transformer
To replace the transformer, you will need the following parts and tools:
Note: The printer uses a different transformer for 220-volt and 115-volt printers.
• XFMR, 3600, 47-63HZ, 100V/120V, Intermec Part No. 585525-001 or
XFMR, 3600, 47-63HZ, 200V/240V, Intermec Part No. 585525-002
• ESD grounding strap
• #2 Phillips screwdriver
To replace the transformer
1. Switch off the printer power and remove the power cord, the media cover,
and the electronics cover.
2. Disconnect the transformer cable from the main PCB and the two leads
with push-on connectors from the AC power plug and the power switch.
Transformer
Screw
(2 places)
Power switch/
circut breaker
Main PCB
5-33
3600 Printer Maintenance Manual
3. Remove the two screws holding the transformer to the base plate and slide
the transformer toward the front of the printer to free it from the metal tabs,
lifting it away from the printer.
4. Install the replacement transformer and push it toward the back of the
printer securing it under the tabs in the printer main deck plate.
5. Secure the transformer to the printer main deck plate with the two screws
removed in Step 3.
6. Reattach the transformer cables to the main PCB, the AC power receptacle,
and the power switch.
7. Install the electronics cover, the media cover, and the power cord, and
check the printer for proper operation.
5-34
PCB Drawings and Schematics
PCB Drawings and Schematics
This chapter contains the assembly drawings, parts lists, and schematic diagrams for
the 3600 main PCB.
PL#
061591
-003
TITLE
: PCB ASSY, MAIN, 3600
PAGE 1/10
PL REV: D
02231995
RUN
DATE:
Feb
23 15:1S
):02
ITEM QTY/UM
PART NO.
REFDES
DESCRIPTION
X
Y F/B
1
1
061590-
-003
PCB, MAIN, 3600
2
0.001
RL
046766
LBL.STK. .2 3HX1 . 5 0L, 4-HI .
4MIL.
3
3
584274
XU6
SOC.32-POSN. DIP, LOW PROFILE
1!
XU8
1!
XU9
4
2
056914
U12
IC, ASIC, THERMAL COMPENSATION
6.5
3.1
F
1!
U32
5.1
3.1
F
5
1
060691-
-001
U25
CONFIG GAL, 16V8, ASIC INTFC
6.9
4.7
F
6
1
060693-
-001
U13
CONFIG GAL, 16V8, DRAM CONTROL
5.7
4.7
F
7
1
061869-
-001
U23
CONFIG GAL, 22V10, ASIC/OPTINTFC
6.3
5.3
F
8
1
061870-
-001
U20
CONFIG GAL, 16V8, DSACK/FIFOCNTL
6.4
4.7
F
9
1
061871-
-001
U21
CONFIG GAL, 16V8, STEP MOT
CNTL
3.5
0.4
F
10
1
550694
R192
RES.CARB 1.00W 5% 820.0
OHM
9.7
1.3
F
11
1
550893
R219
RES,CARB, 2W, 5%, 750.0 OHM
7.8
0.2
F
12
11
551800
R160
RES.S/M, O OHM JUMPER
1.0
2.3
F
R2 5
1.0
1.1
F
R2 51
1.0
2.6
F
R252
1.6
1.1
F
R2 5 3
1.3
1.4
F
R2 5 4
1.0
2.5
F
R2 5 5
1.0
1.0
F
R2 5 6
1.3
1.2
F
R2 5 7
1.0
0.9
F
R2 5 8
1.3
1.3
F
R259
1.6
1.2
F
13
1
555450
R125
RES. POT. SIDE ADJ.W/KNOB
10KOHM
0.3
5.1
F
14
1
555901
R6
RES.S/M. POT TOP ADJ. 100
KOHM
8.4
3.5
F
15
1
555909-
-001
R191
RES, S/M, POT, TOP ADJ, 20 KOHM
8.4
3.1
F
16
2
556600
1!
R214
R224
RES, S/M, FILM, .12W,5%,100
OHM
4.4
4.0
0.7
0.5
F
F
17
16
556603
II
II
II
II
II
II
II
II
II
II
II
II
II
II
II
Rl
Rll
R35
R36
R74
R75
R107
R108
R113
R142
R157
R164
R185
R212
R2 4
R2 41
RES . S/M, FILM, . 12W, 5% 4.7
KOHM
3.2
3.2
5.4
5.4
5.8
6.5
2.8
3.2
3.2
9.5
7.1
6.3
6.6
6.7
1.0
1.3
0.6
0.8
6.0
5.8
4.4
4.0
0.3
1.0
0.1
3.0
4.4
5.2
4.4
3.8
2.5
1.4
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
18
81
556604
II
R2
R3
RES, S/M, FILM, .12W,5%,10
KOHM
5.4
4.7
5.9
6.0
F
F
I
1
R5
1.0
1.1
F
6-3
3600 Printer Maintenance Manual
PL# 061591-003
PL REV: D
RUN DATE: Feb 23 15:19:02
TITLE: PCB ASSY, MAIN, 3600
PAGE 2/10
02231995
ITEM QTY/UM PART NO. REFDES
DESCRIPTION
F/I
R8
R9
RIO
R12
R13
R14
R15
R16
R17
R19
R2
R2 3
R2 4
R2 5
R2 6
R2 7
R2 8
R2 9
R32
R33
R37
R38
R3 9
R40
R41
R42
R4 3
R44
R4 5
R4 6
R4 7
R48
R4 9
R50
R51
R52
R53
R54
R55
R56
R57
R58
R5 9
R60
R61
R62
R63
R64
R65
R66
R67
R68
R69
R70
5
8
4
3
F
4
7
5
9
F
1
3
1
5
F
4
4
5
F
4
4
6
F
3
3
5
8
F
6
8
5
F
6
6
5
F
1
3
5
3
F
4
5
4
F
6
7
3
7
F
5
3
4
F
5
3
4
1
F
2
2
1
7
F
1
7
3
4
F
3
7
5
2
F
3
7
5
3
F
4
5
2
F
1
2
4
F
1
2
1
8
F
3
3
5
8
F
4
5
3
F
3
3
F
3
3
1
F
6
3
F
5
3
F
5
3
3
F
6
3
3
F
5
3
5
F
6
3
5
F
6
4
4
F
6
4
6
F
6
4
7
F
6
4
8
F
6
4
8
F
6
4
9
F
6
5
1
F
6
5
2
F
2
9
3
4
F
2
4
5
2
F
1
3
3
F
1
3
3
1
F
1
3
3
2
F
1
3
3
3
F
1
3
3
4
F
1
3
3
5
F
1
3
3
6
F
1
3
3
7
F
1
3
4
5
F
1
3
4
6
F
1
3
4
7
F
1
3
4
8
F
1
3
4
9
F
1
3
5
F
6-4
PCB Drawings and Schematics
PL# 061591-003
PL REV: D
RUN DATE: Feb 23 15:19:02
TITLE: PCB ASSY, MAIN, 3600
PAGE 3/10
02231995
ITEM QTY/UM PART NO.
REFDES
DESCRIPTION
F/B
19
20
21
22 70
M
R71
II
R72
II
R95
II
R110
II
R118
II
R131
II
R133
II
R134
II
R145
II
R146
II
R153
II
R155
II
R156
II
R158
II
R183
II
R187
II
R193
II
R194
II
R195
II
R201
II
R203
II
R2 04
II
R206
II
R222
556605
R121
II
R2 37
II
R239
556607
R21
II
R96
II
R116
II
R120
II
R141
II
R238
II
R2 4 7
556613
R117
II
R218
II
R229
556629
R7 6
II
R77
II
R78
II
R7 9
II
R80
II
R81
II
R82
II
R83
II
R84
II
R85
II
R8 6
II
R87
II
R88
II
R8 9
II
R90
II
R91
II
R92
RES, S/M, FILM, . 12W, 5%, 47 KOHM
RES, S/M, FILM, . 12W, 5%, 100 KOHM
RES, S/M, FILM, . 12W, 5%, 10 OHM
RES, S/M, FILM, . 12W, 5%, 47 OHM
1.
.3
5.
.1
F
1.
.3
5.
.2
F
4.
.3
3.
.3
F
4.
.4
1.
.2
F
3.
.7
1.
.3
F
8.
.9
4.
.3
F
9.
.2
4.
.0
F
8.
.5
4.
.0
F
3.
.7
1.
.0
F
3.
.5
0.
.8
F
3.
.2
0.
.9
F
4.
.0
5.
.8
F
7.
.1
4.
.3
F
1.
.2
2.
.2
F
2.
.8
0.
.7
F
10.
.0
3.
.8
F
4.
.7
4.
.0
F
7.
.5
4.
.1
F
10.
.0
3.
.9
F
4.
.0
5.
.8
F
4.
.0
5.
.6
F
4.
.0
5.
.7
F
3.
.3
5.
.7
F
2.
.5
2.
.8
F
3.
.5
1.
.0
F
8.
.9
3.
.2
F
10.
.7
2.
.0
F
4.
.7
1.
.2
F
5.
.0
1.
.0
F
9.
.2
4.
.2
F
5.
.0
0.
.2
F
4.
.7
0.
.3
F
10.
.0
3.
.5
F
10.
.1
3.
.4
F
10.
.5
2.
.3
F
10.
.6
1.
.9
F
10.
.5
0.
.1
F
7.
.5
6.
.0
F
7.
.5
5.
.8
F
7.
.5
5.
.9
F
7.
.5
5.
.6
F
7.
.5
5.
.7
F
1.
.7
3.
.3
F
7.
.5
5.
.5
F
7.
.5
5.
.4
F
1.
.7
3.
.1
F
7.
.5
5.
.3
F
1.
.7
3.
.0
F
7.
.5
5.
.2
F
1.
.7
3.
.2
F
2.
.0
3.
.2
F
2.
.0
3.
.0
F
2.
.0
2.
.9
F
2.
.0
3.
.1
F
6-5
3600 Printer Maintenance Manual
PL# 061591-003
PL REV: D
RUN DATE: Feb 23 15:19:02
TITLE: PCB ASSY, MAIN, 3600
PAGE 4/10
02231995
ITEM QTY/UM PART NO.
REFDES
DESCRIPTION
F/I
23
556640
R93
R94
R102
R103
R109
Rill
R112
R130
R139
R140
R154
R159
R161
R162
R163
R165
R166
R167
R168
R169
R170
R171
R172
R173
R174
R175
R176
R177
R178
R179
R180
R181
R182
R184
R197
R205
R209
R211
R213
R215
R220
R221
R227
R232
R233
R2 35
R236
R2 4 2
R2 4 3
R2 4 4
R2 4 5
R246
R248
R198
RES, S/M, FILM, . 12W, 5%, 150 OHM
2
1
6
F
3
7
5
4
F
5
9
9
F
5
9
1
F
5
9
1
1
F
5
9
3
F
9
7
3
8
F
3
2
2
F
4
5
2
F
5
9
1
5
F
3
2
7
F
2
1
7
F
7
5
6
1
F
6
3
5
F
7
5
4
7
F
7
5
4
8
F
7
5
4
6
F
7
5
5
F
7
5
4
9
F
2
2
1
6
F
2
1
9
F
2
1
8
F
7
5
3
7
F
7
5
3
5
F
7
5
3
3
F
7
5
3
F
7
5
3
1
F
7
5
3
2
F
7
5
2
9
F
7
5
4
5
F
7
5
4
4
F
7
5
4
3
F
7
5
4
2
F
7
8
3
9
F
6
1
4
7
F
7
5
3
8
F
7
5
2
8
F
7
5
3
4
F
7
5
3
6
F
5
9
7
F
5
9
1
3
F
5
9
5
F
5
1
1
F
5
1
2
F
5
3
F
5
4
F
4
7
5
F
5
5
5
6
F
3
2
4
F
3
5
1
F
3
2
3
F
3
2
5
F
2
1
F
6
2
3
8
F
6-6
PCB Drawings and Schematics
PL# 061591-003
PL REV: D
RUN DATE: Feb 23 15:19:02
TITLE: PCB ASSY, MAIN, 3600
PAGE 5/10
02231995
ITEM QTY/UM PART NO.
REFDES
DESCRIPTION
F/B
25
5
556648
R34
II
R115
I!
R123
I!
R132
I!
R143
26
9
556650
R105
II
R114
I!
R128
I!
R129
II
R147
II
R216
II
R223
II
R226
II
R230
27
1
556651
R189
28
10
556658
R4
II
R98
II
R122
II
R126
II
R127
II
R137
II
R148
II
R150
II
R199
II
R200
29
1
556665
R136
30
1
556670
R186
31
2
556672
R149
II
R228
32
3
556674
R124
II
R217
II
R2 34
33
1
556676
R106
34
1
556687
R101
35
1
556690
R138
36
1
556692
R196
37
2
556710
R30
II
R104
38
2
556721
R225
II
R231
39
2
556742
R31
II
R73
40
4
556837-301
R119
II
R135
II
R151
II
R152
41
2
556837-161
R7
II
R100
42
4
556838-287
R18
II
R22
II
R97
II
R99
43
4
561008
C65
II
C124
RES, S/M, FILM, . 12W, 5%, 390 OHM
RES, S/M, FILM, . 12W, 5%, 470 OHM
RES, S/M, FILM, . 12W, 5%, 510 OHM
RES, S/M, FILM, . 12W, 5%, 1.0 KOHM
RES, S/M, FILM, . 12W, 5%, 2 . KOHM
RES, S/M, FILM, . 12W, 5%, 3 . 3 KOHM
RES, S/M, FILM, . 12W, 5%, 3 . 9 KOHM
RES, S/M, FILM, . 12W, 5%, 5 . 1 KOHM
RES, S/M, FILM, . 12W, 5%, 6.2 KOHM
RES, S/M, FILM, . 12W, 5%, 22 KOHM
RES, S/M, FILM, . 12W, 5%, 30 KOHM
RES, S/M, FILM, . 12W, 5%, 36 KOHM
RES, S/M, FILM, . 12W, 5%, 330 KOHM
RES, S/M, FILM, . 12W, 5%, 1 .0 MOHM
RES, S/M, FILM, . 12W, 5%, 9.1 MOHM
RES, S/M, FILM, 1/8W, 1%, 1 OHM
RES, S/M, FILM, 1/8W, 1%, 4 . 99KOHMS
RES, S/M, FILM, 1/4W, 1%, 1 .0 OHMS
CAP, ALUM, RDL LEAD, 5 0VMIN, 100UF
3.
.0
6.
.0
F
9.
.2
4.
.4
F
10.
.7
4.
.3
F
9.
.2
4.
.1
F
9.
.2
3.
.5
F
5.
.9
1.
.0
F
5.
.9
1.
.2
F
3.
.5
1.
.1
F
5.
.9
1.
.6
F
5.
.9
1.
.4
F
5.
.9
0.
.2
F
5.
.9
0.
.4
F
5.
.9
0.
.8
F
5.
.9
0.
.6
F
8.
.4
2.
.9
F
1.
.5
0.
.3
F
10.
.4
3.
.4
F
8.
.4
3.
.3
F
0.
.6
5.
.2
F
4.
.0
0.
.7
F
4.
.0
0.
.6
F
10.
.1
3.
.2
F
10.
.7
3.
.0
F
10.
.7
2.
.3
F
10.
.6
2.
.6
F
10.
.7
3.
.5
F
10.
.0
3.
.6
F
10.
.4
3.
.2
F
8.
.9
4.
.1
F
10.
.7
3.
.4
F
4.
.4
0.
.9
F
4.
.0
0.
.9
F
2.
.5
0.
.7
F
2.
.5
0.
.3
F
9.
.5
2.
.8
F
9.
.2
3.
.3
F
5.
.1
5.
.7
F
2.
.8
0.
.8
F
4.
.4
1.
.0
F
4.
.0
1.
.3
F
4.
.9
5.
.7
F
6.
.2
4.
.0
F
6.
.2
0.
.3
F
5.
.0
1.
.4
F
4.
.7
1.
.1
F
4.
.7
0.
.6
F
10.
.6
1.
.7
F
10.
.5
2.
.5
F
7.
.3
1.
.6
F
7.
.3
1.
.8
F
7.
.3
1.
.7
F
7.
.3
1.
.9
F
9.
.7
2.
.1
F
9.
.7
0.
.6
F
6-7
3600 Printer Maintenance Manual
PL# 061591-003
PL REV: D
RUN DATE: Feb 23 15:19:02
TITLE: PCB ASSY, MAIN, 3600
PAGE 6/10
02231995
ITEM QTY/UM PART NO. REFDES
DESCRIPTION
F/I
44
45
46
47
561018-001
561908
563602
I!
563605
49
61
563
563
06
00
C125
C140
C123
C53
C46
C54
C55
C56
C126
C127
C128
C129
C141
C35
C81
C82
CI
C2
C3
C4
C5
C6
C7
C8
CIO
C12
C13
C15
C16
C17
C18
C19
C20
C21
C23
C25
C26
C27
C28
C29
C30
C31
C32
C33
C34
C36
C37
C38
C39
C41
C42
C43
C45
CAP,AL,ELCTLT,R/L, 63V, 12000UF
CAP.AL.R/L 16V 4 7 00. UF
CAP.S/M,TANT, 10V MIN+-20%, 10UF
CAP.S/M,TANT.35V, 20%, 1UF
CAP, S/M, TANT, 6VMIN, 10%, 68UF
CAP, S/M, CER, 50VMIN, 20%, .1 UF
9
7
2
6
F
4
1
2
F
8
1
2
F
6
7
4
F
2
5
2
F
7
6
1
4
F
7
5
3
F
7
2
3
F
1
8
1
F
1
2
7
F
1
5
6
F
1
8
7
F
2
5
8
F
2
9
2
9
F
2
5
1
F
6
8
6
F
1
1
2
F
1
6
3
F
5
8
5
8
F
5
4
5
1
F
4
2
4
3
F
4
2
5
6
F
4
1
5
1
F
4
7
4
2
F
1
1
8
F
4
7
5
8
F
3
7
6
F
4
7
5
7
F
9
2
9
F
2
5
2
F
9
4
6
F
2
2
1
9
F
2
4
3
3
F
3
2
3
3
F
1
5
1
5
F
7
1
3
2
F
5
9
3
1
F
6
3
4
3
F
6
8
4
3
F
3
7
2
1
F
6
5
3
8
F
5
6
4
3
F
6
5
2
4
F
4
2
8
F
4
4
1
1
F
5
5
F
6
4
5
9
F
3
6
2
8
F
3
7
8
F
4
4
8
F
8
9
4
2
F
5
3
8
F
10
5
2
F
6-8
PCB Drawings and Schematics
PL# 061591-003
PL REV: D
RUN DATE: Feb 23 15:19:02
TITLE: PCB ASSY, MAIN, 3600
PAGE 7/10
02231995
ITEM QTY/UM PART NO.
REFDES
DESCRIPTION
F/B
M
C48
II
C50
II
C51
II
C58
II
C60
II
C61
II
C62
II
C64
II
C67
II
C70
II
C72
II
C75
II
C76
II
C107
II
C108
II
C109
II
C110
II
cm
II
C112
II
C113
II
C117
II
C136
II
C137
II
C138
50
4
563701
C9
II
Cll
II
C22
II
C24
51
15
563702
C40
II
C68
II
C96
II
C99
II
C100
II
C101
II
C102
II
C103
II
C104
II
C105
II
C106
II
C131
II
C132
II
C133
II
C134
52
7
563705
C14
II
C52
II
C57
II
C59
II
C66
II
C73
II
C74
53
2
563715
C44
II
C49
54
23
563720
C77
CAP, S/M,CER, 50WVDC, 5%, 10 PF
CAP, S/M,CER, 50WVDC, 5%, 100 PF
CAP, S/M,CER, 50VMIN, 10%, .01 UF
CAP, S/M,CER, 50VMIN, 20%, .22 UF
CAP, S/M,CER, 50VMIN, 5%, 150 PF
5.
.0
1.
.3
F
5.
.5
0.
.8
F
4.
.7
1.
.0
F
4.
.9
5.
.7
F
4.
.4
1.
.3
F
8.
.9
4.
.4
F
5.
.4
0.
.1
F
9.
.8
2.
.8
F
10.
.7
3.
.3
F
10.
.7
3.
.2
F
10.
.5
2.
.9
F
10.
.7
3.
.7
F
3.
.2
2.
.1
F
3.
.5
0.
.9
F
3.
.7
0.
.9
F
4.
.0
0.
.8
F
5.
.2
2.
.4
F
5.
.7
3.
.1
F
5.
.1
3.
.8
F
4.
.5
3.
.1
F
2.
.8
1.
.9
F
8.
.7
4.
.0
F
5.
.3
4.
.3
F
4.
.9
4.
.2
F
5.
.1
5.
.8
F
4.
.9
5.
.8
F
6.
.1
4.
.0
F
6.
.1
3.
.8
F
10.
.7
2.
.5
F
10.
.4
3.
.3
F
10.
.0
3.
.7
F
4.
.3
3.
.4
F
7.
.8
3.
.0
F
7.
.8
3.
.3
F
7.
.8
3.
.5
F
7.
.8
3.
.7
F
7.
.8
3.
.1
F
7.
.8
3.
.2
F
7.
.8
2.
.9
F
7.
.8
3.
.8
F
7.
.8
3.
.6
F
7.
.8
3.
.4
F
7.
.8
2.
.8
F
4.
.7
5.
.6
F
9.
.2
4.
.3
F
0.
.6
5.
.3
F
10.
.4
4.
.0
F
9.
.5
3.
.0
F
9.
.4
3.
.3
F
9.
.4
4.
.1
F
2.
.2
0.
.3
F
2.
.5
0.
.6
F
5.
.3
4.
.8
F
6-9
3600 Printer Maintenance Manual
PL# 061591-003
PL REV: D
RUN DATE: Feb 23 15:19:02
TITLE: PCB ASSY, MAIN, 3600
PAGE 8/10
02231995
ITEM QTY/UM PART NO. REFDES
DESCRIPTION
F/I
M
C78
II
C79
II
C80
I!
C83
I!
C84
II
C85
I!
C86
I!
C87
I!
C88
I!
C89
II
C90
I!
C91
I!
C92
I!
C93
I!
C94
II
C114
I!
C116
I!
C130
I!
C135
I!
C139
II
C143
I!
C144
55
4
563729
C47
11
C95
I!
C97
II
C98
56
2
563731
C63
1!
C142
57
4
563736-001
C115
M
C118
II
C120
I!
C121
58
27
564202
D3
II
D5
II
D7
II
D8
II
D18
II
D19
II
D21
II
D22
II
D23
II
D24
II
D25
II
D29
II
D30
II
D31
II
D32
II
D34
II
D35
II
D36
II
D37
II
D38
II
D40
CAP, S/M,CER, 50VMIN, 10%, 1 UF
CAP, S/M,CERM, . 001UF, 200V, X7R
CAP, S/M, CER, 0603, 25V, . 01UF
DIODE, S/M, TYPE BAS16
4.
.1
4.
.8
F
5.
.3
5.
.4
F
4.
.5
4.
.2
F
2.
.4
3.
.4
F
3.
.2
3.
.4
F
2.
.0
5.
.3
F
5.
.8
5.
.7
F
6.
.3
4.
.4
F
6.
.8
4.
.4
F
5.
.6
4.
.4
F
4.
.0
2.
.9
F
6.
.4
5.
.8
F
3.
.5
2.
.9
F
6.
.5
2.
.5
F
6.
.5
3.
.7
F
5.
.2
2.
.5
F
5.
.1
3.
.7
F
1.
.0
0.
.7
F
3.
.7
0.
.7
F
2.
.8
1.
.8
F
4.
.9
5.
.6
F
5.
.7
5.
.2
F
9.
.3
0.
.3
F
9.
.2
2.
.6
F
10,
.5
0.
.3
F
9.
.3
1.
.1
F
10.
.6
1.
.8
F
1.
.4
0.
.3
F
1.
.5
0.
.5
F
1.
.9
1.
.0
F
1.
.1
0.
.7
F
1.
.9
0.
.8
F
3.
.3
6.
.0
F
3.
.2
5.
.5
F
9.
.0
0.
.6
F
9.
.0
0.
.9
F
10.
.7
1.
.7
F
10.
.7
1.
.5
F
10.
.5
2.
.2
F
4.
.8
1.
.4
F
10.
.7
1.
.3
F
4.
.8
0.
.9
F
4.
.7
0.
.2
F
10.
.5
1.
.2
F
5.
.8
0.
.2
F
4.
.2
0.
.6
F
4.
.4
0.
.6
F
5.
.8
1.
.2
F
5.
.8
0.
.4
F
5.
.8
1.
.5
F
5.
.8
0.
.8
F
5.
.8
1.
.3
F
5.
.8
0.
.6
F
6-10
PCB Drawings and Schematics
PL# 061591-003
PL REV: D
RUN DATE: Feb 23 15:19:02
TITLE: PCB ASSY, MAIN, 3600
PAGE 9/10
02231995
ITEM QTY/UM PART NO.
REFDES
DESCRIPTION
F/B
M
D42
II
D43
I!
D44
I!
D45
II
D46
1!
D47
59
4
564206
Dl
M
D2
II
D4
II
D14
60
1
564217
D28
61
3
564219
D15
II
D16
II
D20
62
1
564235
D9
63
2
564238
D26
II
D27
64
4
564239-002
D6
II
D10
II
D12
II
D13
65
1
565091-001
Q5
66
4
565101
Q2
II
Q9
II
Q10
II
Q16
67
1
565102
Q17
6 8
1
565110
Q7
69
1
565127-001
Q15
70
8
565130-001
Ql
Q3
Q4
Q6
Qll
Q12
Q13
Q14
71
1
567024
VR1
74
1
578020
U28
75
1
578023
U5
76
4
578081
U7
II
U10
II
U14
II
U15
77
1
578087
U4
78
2
578131
Ull
II
U24
79
1
578132
U30
80
1
578134
Ul
81
1
578135
U2 9
82
1
578137
Dll
83
1
578145
Y2
84
2
578209-001
U16
DIODE, S/M, TYPE MMBD301
DIODE, S/M TYPE 5231 ZENER, 5V
DIODE, S/M TYPE 5245 ZENER, 15V
DIODE, S/M, TYPE 522 6, ZENER, 3 . 3V
DIODE, S/M, TYPE BAS21,200VBR
DIODE, S/M, DUAL, 6A, 100V
XSTR,FET, 60V, 30A
TRANS, S/M, NPN, TYPE 4401
TRANS, S/M, TYPE 4403, PNP
XSTR, S/M, TYPE 6427 DARLINGTON
XSTR, S/M,T5551,NPN, 160V
XSTR, S/M, HEXFET, 60V, 7 . 7A
VOLTAGE REGULATOR, 5V, 1A
IC, S/M, TYPE 74HC04
IC, S/M, TYPE 74HC32
IC, S/M, TYPE 74HCT245
IC, S/M, TYPE 14C89,CMOS RCVR
IC, S/M, TYPE IDT72105,FIFO
IC, S/M, TYPE MC145041
IC, S/M, TYPE 75ALS180
IC, S/M, TYPE MC34064
IC, S/M, TYPE LM385-1.2
CRYSTAL, S/M, 24MHZ
IC, S/M, TYPE 74ALS257
4
8
8
F
5
8
1
F
5
3
1
F
4
6
1
4
F
4
6
9
F
4
6
8
F
1
9
6
F
1
8
6
F
3
5
6
F
1
1
2
8
F
10
5
3
F
10
7
1
2
F
9
2
F
10
5
1
5
F
2
5
4
F
9
8
F
9
4
F
7
8
6
F
9
3
7
F
8
7
6
F
8
3
6
F
9
8
2
F
3
4
5
5
F
10
3
3
8
F
10
3
4
F
3
2
1
2
F
10
6
2
7
F
10
5
1
3
F
10
7
2
2
F
6
9
9
F
6
3
9
F
6
9
1
6
F
6
3
1
6
F
6
3
1
3
F
6
9
1
3
F
6
3
2
F
6
9
2
F
7
5
2
F
5
8
5
4
F
3
6
5
7
F
9
3
2
F
9
4
9
F
3
3
2
4
F
3
8
2
4
F
1
2
F
2
1
2
3
F
2
7
2
3
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8
6
4
3
F
1
1
5
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1
8
3
F
2
2
5
F
5
8
3
9
F
3
6
3
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6-11
3600 Printer Maintenance Manual
PL# 061591-003
PL REV: D
RUN DATE: Feb 23 15:19:02
TITLE: PCB ASSY, MAIN, 3600
PAGE 10/10
02231995
ITEM QTY/UM PART NO. REFDES
DESCRIPTION
F/I
M
U18
85
1
578211-
-001
U3
86
3
578245-
II
II
-001
U2
U27
U31
87
1
578294-
-001
U2 6
88
1
578300-
-001
U22
89
2
578301-
II
-001
U17
U19
90 2.
.610
580231
91
1
580285
J10
93
3
580359
II
II
Jll
J12
J13
94
1
580434
Jl
95
1
581976
J14
96
2
581978
II
J9
J15
97
2
582065
II
SW1
SW2
98
1
582282-
-012
J2
99
1
585636-
-001
LI
100
1
586298
BT1
101
1
586548-
-001
Q8
102
1
588000
Yl
103
2
580213
IC,S/M,TYPE MC68332,MICPRCS
IC, S/M,LM2 93,DUAL VOLT COMPTR
IC, S/M,DRAM, 256KX16, SOJ
IC, S/M, 234,RS-232 DRVR
IC, S/M,HIP4081,HF DRVR, 80V
CONN, 2 6-POSN . HDR . SNGL . ROW/ .10
CONN, 8-POSN, HDR, . 156, FRICTION
CONN. HDR. 4-POSN. STRAIGHT THRO.
CONN.25-POSN.D/SUB W/SNAP
CONN, 4 0-POSN,HDR, .1 DBL ROW
CONN, 6-POSN, HDR, .100, FRIC LOCK
SW, 8-POSN. DIP, SIDE ACTUATED
CONN, S/M, PIN, . 8MMX6MM, 80-POSN
INDUCTOR, 10 UH
HLDR. BATTERY, AA SIZE
SENSOR, S/M, REFLECTIVE
CRYSTAL, S/M 32.768 KHZ
CONN. 2-POSN. SHORTING, .10 CTRS .
4.
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3.
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6-12
H H H H
5 4 3 2
REVISION
SHEET
REV STAFUS
OF SHEETS
REVISK
ONS
K_V
CLCCRIPTIDN
DATE
U'n'Ai'/N & AITXOVlL
D
-OS 3 RELEASED AT REV D
E
-004 PER ECN 023890
F
-C05 PER ECN 024053
H
-COS MFG RELEASE
4-27-95
NEDION TOfrNSELL
NOTES: UNLESS OTHERWISE SPECIFIED
1 . CAUTION: THIS ASSEMBLY CONTAINS MOS DEVICE (S) WHICH
MAY BE DAMAGED BY STATIC DISCHARGE. USE SPECIAL HANDLING
PER PROCEDURE 60SO13.
CAUTION
SUBJECT TO DAMAGE BY
STATIC ELECTRICITY
[T^MARK PART NUMBER LABEL, ITEM 2 WITH 061591 AND DASH NUMBER
TO WHICH MANUFACTURED PER PROCESS SPECIFICATION 047233.
CHANGES REQUIRE SAC APPROVAL
PLACE ITEM 90 CONNECTOR PINS AT THE FOLLOWING LOCATIONS
J3,JB,J7,US,TP14 1 TP15 1 TP16.
SEE SEPARATE PARTS LIST FOR 061591-006
■006
NOTICE
THIS DRAWING SHALL NOT BE DUPLICATED OR USED FDR ANY PURPOSE
OTHER THAN THAT FOR WHICH PROVIDED. THE INRORMATION DISCLOSED
HEREIN ORIGINATED BY AND IS THE PROPERTY OF INTERMEC CORPORATION
AND EXCEPT FOR RIGHTS EXPRESSLY GRANTED BY WRITTEN CONSENT, SUCH
NFORNATION SHALL NOT BE DISCLOSED OR DISSEMINATED WHOLE OR IN PART
INTERMEC CORPORATION RE5ERVES ALL PATENT, PROPRIETARY, DESIGN, USE,
SALE, MANUFACTURING AND REPROOUCTION RIGHTS THERETO.
CAD DB.REF-061591-006h.uy1
SYSTEM - VALID 7 ALLEGRO 8.0
UNLESS OTHERWISE
SPECIFIED,
DIMENSIONS ARE
IN INCHES
.XX ±
.XXX ±
ANCLES ± —
APPROVALS DATE
DRAW r PETERSON 11-03-94
ntermec
SDOl 3E-TH AVENUE WEST
EVEREFT, WA 915203-9230
CHECKED
RESP ENG
T ' T PCB ASSY, MAIN
MEMORY EXPANSION, 3400
.SIZE CAGE CODE DRAWING NUMBER
. D 00825 061591
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3600M.075
Replacement Parts
Replacement Parts
This chapter contains a list of 3600 printer replacement parts referenced to
illustrations.
Replacement Parts
The following table is a copy of the 3600 service parts matrix with illustration
references added. It lists the 3600 printer parts that can be ordered for
replacement by the part number indicated. Each part on the list has an ID
number corresponding to a callout on the illustration showing its location.
Multiple ID numbers occur when parts are used more than once or when
another view of the part is called out for clarification. A list of documentation
part numbers you can order is also provided.
To order replacement parts, contact Intermec:
Intermec Corporation
6001 36th Avenue West
P.O. Box 4280
Everett, WA 98203-9280
Note: Only the listed printer parts are spares available for purchase.
3600 Printer Spare Parts List
ID No.
Part Number
Description
01,07
061564-001
BEZEL, TOP COVER
02,99
061550-007
PLATE, MAIN DECK
03, 05, 06, 08,
522690
SCREW, THD ROLL W/CONE
42, 43, 45, 70,
83,86,119,146
04
059101-009
COVER, ELECTRONICS
09
521528-001
TAPE, TRANSFER, ADH, .010 T
10
059710-001
MAGNET, DOOR LATCH
11
059013-002
LENS, MEDIA INSPECTION
12
060622-001
LBL, INTL LOADING INSTRUC
13
061547S-006
COVER, REAR
14,34
061544-004
PLATE, BASE
15
061545S-002
COVER, MEDIA ACCESS
16,46
061546S-004
BEZEL, FRONT COVER
7-3
3600 Printer Maintenance Manual
ID No.
Part Number
Description
17,27
059012-009
PLATE, FRONT COVER
18, 20, 21, 40,
526036
SCREW, PHP, W/INT STAR 6-32 X .375
66, 155
19,54
059052S-001
PCB ASSY, BEZEL
22
059387-003
BRACKET, HINGE
23
060315-002
ROLLER, PINCH
24
061581-001
SHAFT, PINCH ROLLER
25
501445
RING.RTN. .125 DIA. E-RING, ZINC
26,44
061579S-003
DOOR ASSY, MEDIA ACCESS
28,95
061555-001
EXTRUSION, PRINTED SPAN
29, 116
521118-001
WASHER, SPRING, CONL .175 X .50
30
505613
SCREW, SOC HD CAP 8-32
31,56
061548-001
CABLE ASSY, RIBBON PRINTHEAD
32,73
059032-002
BRACKET, PRINTHEAD PIVOT
33,76
061559-003
BLOCK, PIVOT
35
501272-001
FEET, RUBBER, ADHESIVE BACKED
36
061570-003
HEATSINK ASSY, PRINTHEAD
37
505767
SCREW, PHM, 8-32X .375
38
061611S-001
PRINTHEAD, 6.6 INCH, 5 MIL, 3600
39
062862-002
CAP, BIAS SCREW
41,87
061556-004
PLATE, LOWER MODULE, OUTBD
47
059103-002
BUTTON, CAP
48
058776-004
LIGHT PIPE, DOCK/CHARG
49
061591S-005/061591E-005*
PCB ASSY, MAIN (^exchange part no.)
50,55
059727-001
CABLE ASSEMBLY, BEZEL
51,98
059496-004
CABLE ASSY., LABEL TAKEN SENSOR
52
061578-001
CABLE ASSY, LBL MARK SENSOR
53, 123
059495-001
CABLE ASSY, LABEL GAP
57
586142
INS. SHIM
58
507846
SPACER, .235 RD. NY. SHOULDER
59
505312
SCREW, PHM, PHIL 4-40X.25
60
061549-003
HEATSINK, PCB DRIVERS
7-4
Replacement Parts
ID No.
Part Number
Description
61
585525-001
XFMR, 3600, 47-63HZ, 100V/120V
585525-002
XFMR, 3600, 47-63HZ, 200V/ 240V
62
041776
JUMPER AY, .25 TERM. LUGS, 4-IN
63
060246-001
FILTER ASSY, LINE AC
64
506103
WASHER, LOCK, EXT. STAR, NO.
65
501273-001
CIRCUIT BREAKER, SWITCH, 2 AMP
65
501273-002
CIRCUIT BREAKER, SWITCH, 1 AMP
67
506111
WASH. LOCK. SPLIT, NO. 4
68
060544-001
GASKET, ESD, RS232 CONNECT
69
507659-001
SCREW, JACK, 4-40X .312
71
586229
BATTERY, LITHIUM 3.6V, 1.75AH
72, 145
525034-001
SCREW, THD ROLL W/CONE, 8-
74, 93, 106,
506013
WASHER, SST, .255ID X .407OD
108, 132
75
506827-001
SPRING, COMP. 360 OD .44F
77
059122-001
LEVER, PRINTHEAD ADJUSTMENT
78
507717
FASTENER, COTTER PIN 25
79
061561-001
SPRING, TORSION, PRINTHEAD RETURN
80
061560-001
SHAFT, TTR RIBBON
81, 100, 136
501409
RETAINING RING .250 DIA BASIC
82
059039-011
HANDLE, PRINTHEAD PRESSURE
84
063225-001
PLATE, UPPER MODULE, OUTBD
85
061576S-002
CAM ASSEMBLY, HEAD PRESSURE
88
061568-002
ROLLER, LINER DRIVE
89
061542-003
ROLLER, PLATEN
90
061543-002
ROLLER, DRIVE
91
061558-002
BAR, STRIP SUPPORT
92, 109, 134
501401
RTN RING .250 DIA 8610/2
94
061541-001
BAR, TEAR
96, 131
501394-001
MOUNT, WIRE ROUTING, ADH B
97
059423-002
MOUNT, MARK SENSOR
7-5
3600 Printer Maintenance Manual
ID No.
Part Number
Description
101
061902-001
ARM, MEDIA BRAKE
102
062352-002
BELT, FLAT POLYURETHANE, 1.75 ID
103
061900-003
DRUM, MEDIA BRAKE
104
062746-002
BUSHING, MEDIA ARM
105
506022
WASHER, NYLON, .257ID X .5
107
061587-005
PLATE, INBOARD MEDIA SUPPLY
110
061903-001
POST, MEDIA SUPPLY
111
061586-003
ROLLER, MEDIA SUPPLY
112
059718-002
RING, LABEL SUPPLY
113
061904-002
CAP, MEDIA SUPPLY
114
061552-003
BRACKET, MEDIA PATH, UPPER
115
059030-005
EDGEGUIDE, OUTER
117
059781-001
THUMBSCREW, ASSEMBLY
118
061553-003
BRACKET, MEDIA PATH, LOWER
120
061567-002
SPRING, TORSION, PAPER PATH
121
059509-002
SHAFT, PAPER PATH
122
062396-001
MOUNT, LBL GAP SENSOR
124
061901-001
PEDAL, MEDIA BRAKE
125, 127, 165
061562-005
HUB ASSY
128
061566-003
BRACKET, CORE LOCKING
129, 142, 150
506040-005
WASHER, FLAT SST .327 X .50 X .30
130
060214-001
FLAP, PRINTHEAD CBL RESTR
133
061563-002
GEAR/PULLEY, CLUSTER, L/H
135
061557-003
GEAR, PLATEN, D SHAFT
137
061569-002
GEAR/PULLEY CLUSTER, RH
138
506040-004
WASHER, FLAT SST, .817 X 1.0
139
062927S-001
CLUTCH, ASSY, RIBBON TRANSPORT TAKE-UP, 3600
SPARE
140
506049-001
WASHER, FLAT, NYLON .320ID
141, 160
501461-001
RETAINING RING EXTERNAL .395
143, 152
501410
RETAINING RING .310 DIA, GRIPPING
7-6
Replacement Parts
ID No.
Part Number
Description
144
061551-002
CABLE ASSY, MOTOR MAIN STEPPER
147
059102-002
BRACKET, MOTOR MOUNT
148
061554-004
PLATE, MOTOR
149
061584-002
SUBPLATE, LINER TAKEUP
151, 154
505359-001
SCREW, W/CONE WASH, 8-32X1
153
061588-002
GEAR, LINER REVERSE
156
062603-001
PLATE, HUB ADJUST
157
061583-002
SUBPLATE, TTR
158
061574S-001
CLUTCH, ASSY, SELF STRIP LINER TAKE-UP, 3600 SPARE
159
506040-007
WASHER, FLAT SST 446 X .56
161
061589-001
SHAFT, LINER REVERSE
162, 163
501462-003
O-RING, 2.800ID X .210THK
164
506040-006
WASHER, FLAT SST .327 X .500 X .080
166
061565-002
CLAMP, LINER HUB
not shown
061605-001
CORE, RIBBON, 3600, CDBD, 6.7 IN.
not shown
062197S-003
FIRMWARE, 3600, VER 1.1, SPARE
3600 Manuals
Part No.
Description
062732-001
062733-001
3600 Bar Code Label Printer User's Manual
3600 Bar Code Label Printer Getting Started Guide
7-7
3600M.092
Appendix
Appendix
This appendix describes the theory of operation for the 3600 printer.
Functional Description of the 3600 Mechanics
This section describes the basic mechanical functionality of the 3600 printer.
The 3600 printer has a sheet metal frame (base plate and main deck plate) to
which mechanical and electrical components are attached. The printer holds,
moves, routes for contact by the printhead, and stores label stock and ribbon by
electronically controlled mechanical means. Sheet metal covers protect media
and components.
The printer has one electrically powered motor that is the source of
simultaneous movement for all of the driven parts. The motor shaft uses a
pinion gear to impart drive force to the rotating parts, producing ribbon and
liner movement.
The motor pinion gear drives the platen roller by meshing with the 96-tooth
gear mounted on the end of the roller. The platen roller gear contacts a 96-tooth
gear /pulley assembly on the TTR drive roller, assisting ribbon movement and
providing drive to the TTR takeup hub by means of the drive belt (O-ring)
between the TTR drive gear/pulley and the TTR takeup clutch/pulley.
The motor pinion gear also meshes with a 96-tooth gear/pulley on the liner
drive roller, assisting liner movement and providing drive to the liner takeup
hub by means of another drive belt between the liner drive gear/pulley and the
liner takeup clutch/pulley.
The liner takeup clutch/pulley rotates an idler shaft and gear that meshes with
an identical gear on the liner takeup hub shaft to produce reverse rotation of
the liner takeup hub.
The TTR drive function and the liner drive function each use one-way clutches
to facilitate label retract. A one-way clutch is part of each roller drive gear. The
TTR drive roller gear is white, while the liner drive roller gear is black. This
makes it easy to distinguish between the two gears, which is necessary because
the clutches are one-way in opposite directions and would not work if
interchanged.
The clutch /pulley assemblies on the TTR takeup hub and liner reverse shaft
are similarly color coded because they have different torque values. The
springs inside are color coded as well: TTR = white gear, white pulley/clutch,
white spring (inside); liner = black gear, black pulley/ clutch, black spring.
The belt driven TTR takeup (16 in-oz) hub and liner reverse (34 in-oz) idler
shaft use one-way clutches that manage takeup force and prevent slackening
during retract. Reversed liner takeup rotation produces less slippage.
The TTR supply hub uses an 18 in-oz slip clutch. The hub has a TTR encoder
sense label attached to it that is used for ribbon motion sensing.
A-3
3600 Printer Maintenance Manual
A media supply assist roller and brake assembly are part of the media supply
post function. The free spinning roller reduces the drag of the media core over
the stationary supply post, allowing the media to turn smoothly during
printing. When printing stops, the media slackens under the upper media
guide, causing the media brake pedal and brake arm to lower onto the rubber
contact strip on the brake drum, which inhibits media roll momentum by
stopping the assist roller.
Functional Description of the 3600 Electronics
This section describes the basic electronic functionality of the 3600 printer.
Components are identified by the reference designators used on the schematic
diagrams (provided in Chapter 6).
Power Supply
The power supply for the 3600 is primarily a linear supply with a switching
buck converter for the 24V printhead supply. The switching buck converter
takes the unregulated +50V and uses a switching transistor to reduce the
output voltage to +24V. The base mechanism is equipped with an AC input
filter and a transformer that supplies the board 12 VAC and 50 VAC.
+5V
The +5V supply is generated from the 12 VAC inputs on connector J10. Diode
bridge D12 rectifies the AC voltage and regulator VR1 regulates the DC voltage
to +5V. Capacitors C53 through C56 are used for filtering and storing energy
for hold time at power down or blackout. VR1 is rated at 1.5 A and is
sufficiently heatsinked to handle this amount of current. The typical +5V load
is approximately 1A.
+40V
The +40V supply is generated from the 40 VAC inputs on connector J10. Diode
bridge D13 rectifies the AC voltage capacitors C95 and C58 that are used as
filters. 40 VAC is unregulated and used for the stepper motor voltage. The
+40V supply is also zenered down to 5.1V to supply the motor logic. This
prevents excessive motor currents on power up. Another zener diode is used to
supply 15V that is used by the +24V buck converter.
+24V
The +24V supply is generated by a switching buck converter.
A-4
Appendix
Power Fail Detection
The power fail detection circuitry consists of IC U31, diodes D7, D8, D9, and
Dll and various resistors and capacitors. Diodes D7 and D8 rectify the
incoming 12 VAC, and R101 and R107 act as a divider. D9 is a zener diode used
to prevent the input on U31 from exceeding +5V. Dll is a 1.235V reference.
When the voltage at pin 3 of U31 exceeds 1.235V, the output is pulled up by a
10K resistor, R183. R104 adds some hysterisis to help filter out noise or
brownouts. C44 and C49 are also for filtering. C46 and R107 set up a time
constant of 1 .5 60 Hz cycles to filter out brownouts. The hold time of the +5V
varies with line voltage and the state of the printer. The printer exceeds 20 ms
at low line and when not printing.
Battery
The battery is used to back up the static RAM for font, format, and UDC
storage. R34 limits the reverse current into the battery, a safety requirement for
lithium batteries. The battery itself is a 3.6V lithium battery with 1.75 Ah. Diode
D4 is a low leakage schottky diode used to isolate the battery voltage from
VCC of the circuit card when the power is off, but it has minimal voltage drop
to RAMVCC when power is on. Transistor Q2 and IC U5 cause the RAM chip
select to be held in a high (inactive) state when /RESET is low to prevent
inadvertent writes to RAM during power up or power down.
Battery Life Calculations
Battery capacity = 1.75 Ah
RAM Data Retention current = 20 |iA maximum, 1 |iA typical
With printer off all the time and worse case scenario:
Battery life = 1.75 Ah / 20 |iA = 87,500 hours = 10 years
With printer off all the time and typical case:
Battery life = 1.75 Ah / 1 jjA = 1,750,000 hours = 200 years
Reset
/RESET is generated by MKC34064 under voltage sensing circuit, U29. The
output of U29 is low for any supply voltage less than 4.6V.
A-5
3600 Printer Maintenance Manual
Motor Driver
The motor driver circuit of the 3600 consists of ICs U2, U21, U17, and U19;
discreet parts Q16, Ql, Q3, Q4, Q6, Qll, Q12, Q13, Q14; and associated diodes,
resistors, and capacitors. The eight D-MOS FETs make up a dual full-bridge
motor driver. There are four FETs to drive each motor phase. There are two
FETs at each end of each motor phase.
When a phase is driven or turned on, one FET on each end of a phase is turned
on. One of the FETs will be a high side FET putting 50 volts on one end of the
winding. The other FET will be a low side FET putting zero volts on that end of
the winding.
When the motor is running the windings are being excited first with 50 volts on
one end, and then the 50 volts on the other end. At no time are both FETs on
the same end of a winding on at the same time.
When a winding is turned on, the current is first monitored and then controlled
by turning the FETs on and off at a high rate. This is called pulse width
modulation. The current in the winding is monitored measuring the voltage
across the sense resistors R18, R22, R97, and R99. These voltages are called
sense_Al and sense_Bl. These voltages are inputs to U2. U2 is a comparator
that compares a reference voltage (voltage at U2 pins 2 and 6) to the voltages
sense_Al and sense_Bl. When these voltages become greater than the sense
voltage the associated out put of U2 switches from low to high. This voltage is
fed into the GAL U21 and then to the appropriate driver IC U17 or U19 which
turns the associate FET off. The off time during this pulse width modulation
cycle is constant and controlled by the C109, R127 for sense_Al or C42, R137
for sense_Bl.
The reference voltage on pins 2 and 6 of U2 is established by the pulse width
modulation input M5. This is an input from the microprocessor to Q15 through
R108. The duty cycle of this signal controls the reference voltage input to U2.
The magnitude of this voltage establishes the magnitude of the current in
motor windings.
Other inputs from the microprocessor to the GAL U21 circuit are Ml, M2, M3,
and M4. These inputs control the stepping of the motor. They go into the GAL
where they are decoded and fed into the driver ICs U17, U19 which turn the
FETs on and off.
Reset is the last input to the motor driver circuit. U19 pin 3 is high when reset
is applied to the DISABLE input of U17. This action ensures that all the FETs
are held in the off condition to control start up and shut down transients.
A-6
Appendix
Processor
The processor used in the 3600 is a MMC68332 32-bit integrated
microcontroller. Based on the MC68020, the MC68332 contains four peripheral
modules: CPU32, a 32-bit central processing unit; TPU, a complex,
programmable time processor unit; QSM, a queued serial module; and SIM, a
system integration module. The MC68332 was chosen for its 32-bit processing
power along with its high level of integration.
Chip Selects
The SIM of the MC68332 allows up to 12 chip selects to be programmed by the
software for use in the system. We use seven of these chip selects. /CSBOOT is
used to access the EPROM of the system. It can handle up to 1M of EPROM
organized as 512K x 16. /CSO and CS1 are used for accessing DRAM, which is
configured as 512K x 16. /CS2 is used to access the static RAM, which is used
for font, format, and UDC storage. /CS3 is used to access the ASIC and I/O
option port. U23 then decodes these chip selects using address lines. /CS4 is
used for interrupt acknowledge. /CS5 combines the chip selects for both
loading the FIFO with image data and also for reading the DIP switches. U20
decodes these chip selects using address lines A16 and A17. /CS6 is used as
A19. /CS7, /CS8, and /CS9 are reserved to be used as A20, A21, and A22 for
possible memory expansion.
TPU
The TPU is the time processor unit of the MC68332. It has 16 programmable
channels that can be used to generate output waveforms or capture input
signals. All of the 16 channels are used in the 3600 printer design. The TPU
contains built-in functions, but it is also possible to override these functions by
downloading new functions into the MC68332 standby RAM. The 3600 design
uses custom TPU functions to perform the following tasks:
Channel This input captures the /STPINT signal. When /STPINT goes
active, channel interrupts the CPU to indicate a step, links to channels 1
through 6 and 10, and sets up a match for the half-step time.
Channels 1 to 4 These outputs control motor signals Ml to M4 respectively.
After initialization to set up motor direction, each channel outputs the next bit
of a programmable bit pattern whenever a link is received from channel 0. A
fixed delay is set for each channel to ensure that all four channels switch
simultaneously.
Channel 5 This output generates the duration portion of the strobe waveform.
A pulse is generated after a link from channel 0. You can program the pulse
delay and width.
Channel 6 This output generates the chopped portion of the strobe waveform.
A continuous square wave is generated and synchronized with each link from
channel 0. The square wave frequency and duty cycle are programmable.
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3600 Printer Maintenance Manual
Channels 7 and 8 These outputs control the front panel LEDs. They can be set
to high, low, or square wave outputs. The square wave output frequency is
programmable.
Channel 9 This output is reserved. It has RXD as an input for autodetection of
the serial communications parameters.
Channel 10 This is an input for the ribbon sensor. The channel detects
transitions on the input. If it does not receive a transition before it receives a
programmable number of links from channel 0, it interrupts the CPU to
indicate a ribbon failure.
Channel 11 This output generates the refresh requests for the DRAM. It
generates a low pulse at a programmable frequency and duration.
Channel 12 This is an input for the front panel switch. It detects transitions on
the input, debounces the switch, and interrupts the CPU.
Channel 13 This output generates a square wave of a programmable
frequency. It is used to set the current level for the motor driver circuit.
Channel 14 and 15 These channels are reserved to support a cutter or a wand
port.
QSM
The QSM consists of two modules, a serial peripheral interface (SPI) and serial
communications interface (SCI). The SPI is used to communicate with the A/D
converter. It takes continuous readings and stores the values in RAM for
immediate access by the CPU. The SCI is used for RS-232/RS-485
communications. Other pins are used as general purpose I/O.
Interrupt Priority Levels
The SIM module has seven IRQ pins to help facilitate external interrupts in the
3600:
• /I/ORCV, /I/OXMT, /PFAIL, and HF are available as interrupts.
• /I/ORCV and /I/OXMT are used for communications with the I/O option
interface.
• HF is used to indicate that the FIFO needs service.
• /PFAIL indicates a loss of power.
• The IRQ pins are used for general purpose I/O.
Crystal
The clock synthesizer of the MC68332 can operate from an on-chip, phase-
locked loop using an external crystal. A 32.768KHz crystal provides a reference,
allowing the processor to run at frequencies from 131KHz to 16.777MHz. The
clock synthesizer is programmed to run at 16MHz in the 3600.
A-8
Appendix
Memory
The MC68332 has separate address busses and data busses. All I/O is memory
mapped and the SIM chip selects are used to select program space, data space,
and I/O.
Static RAM
The 3600 comes with 128K of battery backed static RAM. The RAM is
configured as 128Kx8. The chip select for accessing SRAM should be
configured to at least one wait state. The RAM can also be upgraded to
512K x 8 by swapping the component at location U6. The jumper between pins
1 and 2 of J3 must be removed and placed across pins 2 and 3.
RAM Access Time
Processor access time >= RAM access time
3 x CLK >= Tcslow + Tramaccess + Tsetup + Thc32
3 x 1/16 MHz >= 30 ns + 120 ns + 5 ns + 18 ns
187.5 ns >=173 ns
EPROM
The EPROM for the 3600 consists of two 512K x 8 EPROMs configured as 512K
x 16, giving a total of 1M of EPROM space. The EPROMs have an access time
of 150 ns and do not require wait states.
EPROM Access Time
Processor access time >= EPROM access time
2 x CLK >= Tcslow + Tepromaccess + Tsetup
2 x 1/16 MHz >= 30 ns + 70 ns +5 ns
125 ns >= 105 ns
DRAM
The main memory consists of 256K of dynamic RAM. The DRAM is configured
as 256K x 16, IC U26. To support the DRAM interface, GAL U13 is used to
handle refresh and control lines between the DRAM and the processor. See
Part II, Appendix A for GAL listings of the current configuration. Multiplexors
U16, U18, and U20 are used to generate the row and column addresses for the
DRAM.
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3600 Printer Maintenance Manual
Communications Interface
The communications interface for the 3600 follows the Intermec Standard Data
Connector standard. Jl is a 25 pin D-sub connector that supports both RS-232
and RS-485 interfaces. Ul is the RS-485 driver /receiver and U22 and U4 are the
RS-232 driver and receivers. To further enhance the interface to support
DTR/RTS flow control, the DTR pin is driven with the PIN 14 signal. This
arrangement allows the use of standard cables for hardware flow control,
which enables the user to use commands such as the DOS COPY command
from any PC. Zero ohm resistors have been incorporated into the RS-232 driver
outputs so that the previous configuration or other configurations are possible.
A/D Converter
The Motorola MC145041 A/D converter is an 11-channel, 8-bit, serial A/D
converter. The reference is set to +5V. Seven of the eleven channels are used:
Channel Function
Label gap sensor
1 Darkness adjust
2 Printhead thermistor
3 Label mark sensor
4 +40V
5 Printhead voltage, +24V
6 Label taken sensor
The A/D converter is continuously communicating with the MC68332 through
the SPI. It receives conversion commands and channel addresses while sending
back results from the previous command. The clock rate for the MC145041 is
1MHz.
DIP Switches
The 3600 has 16 DIP switches to provide configuration and test and service
operation.
ASIC and I/O Option Interface
The 3600 uses an Intermec designed thermal compensation ASIC. This ASIC
handles the loading of the printhead to implement the dot-by-dot thermal
management scheme.
Address/Data Multiplexor
Since both the ASIC and the I/O option interfaces are designed to interface
with a processor that has multiplexed address and data, it is necessary to
multiplex the address and data from the MC68332. ICs U14 and U15 are used
to route address or data to the AD (0:7) bus.
A-10
Appendix
Chip Select Generation
GALs U23 and U25 are designed to take the MC68332 bus control signals and
convert them into ASIC and I/O option control signals. A state machine
governs the timing of the signals and also dictates that the /OPTION_ASICCS
from the processor be programmed for two wait states.
I/O Option Connector
The I/O option connector J8 is a 40-position pin field. Two chip selects,
/OPTION* and /BOKI/O*, are used to select either the board identification
number or the data port. XMT and RCV are outputs from the I/O option cards
that are inverted and go to the processor to generate communications
interrupts.
JlFO
The FIFOs Ull and U24 are the same part as used in the Intermec 3400 and
4400 printers. The IDT 72105 is a 256 x 16 FIFO with parallel inputs and serial
output. The processor loads image data into the FIFO with word writes. At the
beginning of a line, the MC68332 loads three lines of data into the FIFO. This
causes the HF flag to go high. The ASIC then begins clocking data out of the
FIFO. The processor checks each line of the HF flag and loads the next line of
data if there is still more image to load. If the image has been completely
loaded, the FIFO empties and the /EF flag goes low. The low /EF flag tells the
ASIC to stop clocking data from the FIFO.
Front Panel Interface
Connector J15 connects to the front panel board. Inputs consist of one button
(Feed/Pause) and three LEDs (Power, Alert, and Empty/Pause). The Alert
LED indicates system errors or printhead over-temperature. The Empty/Pause
LED indicates a paused state or a media fault.
Debug Interface
J5 provides a debug interface to the processor, which allows for
troubleshooting of the main PCB. This interface can be used to put the
processor into background mode and then send commands to read or write
memory or register locations. This interface is used for in-house functional
testing and is used for engineering development.
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3600 Printer Maintenance Manual
Timing
Row
Name
Formula
Min
Max
Margin
Comment
ID
Tclsa
[3,30]
3
30
332 Clk low to sel asserted
2V
Tco
[2,10]
2
10
GAL Clk to output delay
3D
Tchav
[2,39]
2
39
332 Clk hi to add valid
4D
Tsy
[Tsy
4
12
5C
Trah
[15,]
15
<13.25>
DRAM row add hold time
6C
Taist
[5,]
5
<38.50>
332 DSACK setup time
7D
Tclsn
[3,30]
3
30
332 Clk low to sel negated
8D
Tsy
Tsy
4
12
9V
Tpd
[3,15]
3
15
GAL Tpd
IOC
Tasc
[0,]
<6.25>
DRAM col add setup
11C
Tasr
[0,]
<65.75>
DRAM row add setup
12C
Tras
[80,]
80
<38>
DRAM ras low time
13C
Tds
[25,]
25
<18.50>
DRAM
14V
Tsy
[4,12]
4
12
Sel to output HC257
15D
Tpd
Tpd
3
15
16D
Tpd
Tpd
3
15
17D
Tco
Tco
2
10
18D
Tpd
Tpd
3
15
19D
Tco
Tco
2
10
20D
Tpd
Tpd
3
15
21C
Teas
[20,]
20
<35.50>
22D
Tclsa
[3,30]
3
30
Same as 1
23C
Trp
[60,]
60
<52>
24C
Tcah
[20,]
20
<70.75>
25D
Tco
Tco
2
10
26D
Tpd
Tpd
3
15
27D
Tco
Tco
2
10
28D
Tchav
[2,39]
2
39
29C
Tasr
[0,]
<65.75>
30D
Tco
Tco
2
10
31C
Trpc
[10,]
10
<39.50>
32D
Tco
Tco
2
10
33D
Tco
Tco
2
10
34D
Tclsn
[3,30]
3
30
35D
Tclsa
[3,30]
3
30
36D
Tco
Tco
2
10
37C
Trp
[60,]
60
<57>
A-12
Ons
100ns
200ns
300ns
400ns
500ns
600ns
addsel
dsack
§ add K
Ǥ
3
3
a*
to
3600 Printer Maintenance Manual
Functional Description of the 3600 Software
This section describes the basic software functionality of the 3600 printer.
Band Buffering and Font Caching
Image band buffering and font caching allow Intermec printers to image and
print labels at the same time. Virtually any label length can be accommodated
due to the circular system of using image memory. After an image band has
printed, it is reused to image the next part of the label, which means the printer
can print labels using less memory.
Image Band Buffering
Printer throughput is affected by the number of image bands and the print
speed. If imaging is fast enough, throughput will be maximized by using the
least number of image bands with the fastest speed (assuming the fastest speed
delivers the desired print quality).
Some printers use a fixed size, contiguous portion of RAM for imaging. In
these cases, a label is imaged in its entirety before printing commences. During
printing, there is no contention with imaging, so the print speed can remain
constant. However, if the label is fairly complex, the delay before printing
becomes very noticeable. In addition, printing of the label must finish before a
second label is imaged. The combination of these delays impede total printer
throughput. Another drawback is that the maximum length of a label is limited
by the size of the RAM.
With the use of image band buffers (1 band = 1 inch), labels are divided up and
imaged band by band. Printing begins after the selected number of image
bands is imaged, minimizing the delay before printing. Imaging of a second
label can begin while a first is still printing. In addition, the length of a label is
virtually unlimited.
With image band buffering, time becomes a critical resource since printing and
imaging take place simultaneously. Sometimes, a label cannot be imaged fast
enough to keep up with the print speed. The 3600 printer maintains a constant
print speed regardless of label complexity.
Label throughput can be fine-tuned by selecting the number of image bands
and print speed for a specific label format. Selecting image bands determines
how much of a label is preimaged before printing starts.
Selecting too many image bands can lead to print delay. If too few image bands
are selected, imaging falls behind the print speed. If imaging falls behind
printing, the printer stops printing the label, sets the speed to 2 ips, sets the
number of image bands to the maximum, and then reprints the label. This
condition is known as an image rate error or an image overrun error.
A-14
Appendix
The ideal setting keeps imaging just ahead of printing. This ideal setting can be
found by the proper selection of image bands and print speed for the label
format being printed.
Image Band Example
The following example shows a format print using image bands. The label is 5
inches long and is divided into five image bands. The printer is configured for
three image bands, which means that three bands will be imaged before
printing begins.
The dashed lines represent the divisions between the five image bands and the
arrow (T) represents the portion of the image band that is being printed at that
time.
The first diagram shows the first 1 inch of the label imaged into the first image
band. The other two image bands are still empty. Printing has not begun.
E£E
E
The second 1 inch of label is imaged into the second image band. Printing has
still not begun.
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3600 Printer Maintenance Manual
Ij&SIBIIKF!
The third 1 inch of the label is imaged into the third image band. Printing
begins from the first image band, as indicated by the arrow. At this point, all
three available image bands have been filled. The first band will be reused after
it has been completely printed.
When the first image band is emptied (printed), the fourth band is imaged into
it. Printing continues from the second image band. As before, this band must
be emptied before the final band can be imaged into it.
A-16
Appendix
The final 1 inch of the label is imaged into the second image band. Printing
continues from the third band. At this point, the label has been completely
imaged but printing has not finished.
After the third image band is emptied, printing continues from the first image
band.
Imaging of a second label could begin in the third image band while the first
label is still printing. The second label could begin printing immediately after
the first with no delay, which suggests that the only print delay encountered
would be during the time when the first bands of the first label were imaged.
As labels become more complex, the influence that print speed and the number
of buffers has on throughput is limited by imaging speed. New considerations
come in to play, such as delay between printing and perceived printer
performance. Unfortunately, there is no formula to use to calculate an ideal
configuration. Instead, it will have to be found through trial and error by the
user.
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3600 Printer Maintenance Manual
Font Caching
Most of the imaging time during text creation is spent converting character
description data into character images. The remainder of the time is used to
copy the character images into image RAM. Font caching helps to eliminate the
reimaging of characters that have already been used.
With font caching, a character is imaged into the cache the first time it is
requested. It is then copied from the cache into the appropriate area of image
RAM. The next time that same character is needed, it only has to be copied
from the font cache. The illustration on the following page shows the process of
generating and caching a specified character.
When used with band buffering, even if there are no repeated characters in a
label, font caching may still enhance imaging. If a character is large or is
positioned near a band boundary, portions of its image may fall into multiple
bands. The character's image will be referenced repeatedly as each of the bands
is imaged. As before, if the character is cached, it will only need to be imaged a
single time.
Print Energy Compensation
The digital thermal compensation system and the global compensation system
combine to provide the printer with maximum printhead energy control to
optimize print quality.
Digital Thermal Compensation
Each dot on the printhead has its own history RAM. This RAM contains a dot's
previous burn history, what the current burn will be, and what adjacent dots
are doing. This data, along with the media sensitivity information, is used to
determine the proper amount of energy for that dot.
For example, if the dot history showed that the dot had been turned on most of
the time, this profile would indicate that the energy built up in the dot area was
sufficient enough for the task and the dot would be turned off for a period of
time. Using this method provides for a specific amount of energy for the task
that dot is performing.
Global Compensation
Global compensation is the energy management to the printhead that affects all
of the dots on the printhead. External inputs to this system are the darkness
adjust control and the online darkness command. Other inputs include the
ambient temperature, the printhead resistance, and printhead temperature.
A-18
Appendix
Font Caching Flow Chart
Request for
character
Character already
exists in cache
Check cache for
requested character
Character does
not exist in cache
Available memory
is returned
Allocate memory
in cache
for character
No memory
is available
Image character
in allocated cache
Image character
in reserve cache
Return
requested
character
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